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Rev. AD.01 Date: April 2, 2007 Manual # 0-4641Operating Features:

Operating Manual

AUTOMATEDPLASMA CUTTING SYSTEM

CUTMASTER™

Art # A-04611

SL100SVPLASMA CUTTINGMACHINE TORCH

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Dynamics product. We areproud to have you as our customer and will strive to provide youwith the best service and reliability in the industry. This product isbacked by our extensive warranty and world-wide service network.To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.com.

This Operating Manual has been designed to instruct you on thecorrect use and operation of your Thermal Dynamics product.Your satisfaction with this product and its safe operation is ourultimate concern. Therefore please take the time to read the entiremanual, especially the Safety Precautions. They will help you toavoid potential hazards that may exist when working with thisproduct.

YOU ARE IN GOOD COMPANY!The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automationPlasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time.We pride ourselves on technical innovation, competitive prices,excellent delivery, superior customer service and technicalsupport, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologicallyadvanced products to achieve a safer working environment withinthe welding industry.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat-ing, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, theManufacturer assumes no liability for its use.

Automated Plasma Cutting SystemAutomated CutMaster™ 81 Power SupplySL100 Machine TorchOperating Manual Number 0-4641

Covered under U.S. Patents.

Published by:Thermal Dynamics Corporation82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711

www.thermal-dynamics.com

© Copyright 2004, 2005, 2006, 2007 byThermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the pub-lisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for anyloss or damage caused by any error or omission in this Manual, whether such errorresults from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: April 2, 2007

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-11.02 Important Safety Precautions ....................................................................... 1-11.03 Publications .................................................................................................. 1-31.04 Note, Attention et Avertissement .................................................................. 1-31.05 Precautions De Securite Importantes ........................................................... 1-41.06 Documents De Reference ............................................................................. 1-51.07 Declaration of Conformity ............................................................................. 1-71.08 Statement of Warranty .................................................................................. 1-8

SECTION 2: SPECIFICATIONS ................................................................................................ 2-1

2.01 Scope of Manual .......................................................................................... 2-12.02 Power Supply Specifications......................................................................... 2-12.03 Input Wiring Specifications ........................................................................... 2-22.04 Power Supply Features ................................................................................. 2-32.05 Power Supply Options and Accessories ....................................................... 2-42.06 Torch Specifications ..................................................................................... 2-52.07 Torch Options and Accessories .................................................................... 2-62.08 Introduction to Plasma.................................................................................. 2-7

SECTION 3: INSTALLATION ..................................................................................................... 3-1

3.01 Unpacking .................................................................................................... 3-13.02 Lifting Options .............................................................................................. 3-13.03 Primary Input Power Connections ................................................................. 3-23.04 Gas Connections .......................................................................................... 3-43.05 Torch Connections ........................................................................................ 3-73.06 Torch Installation .......................................................................................... 3-93.07 Torch Parts Selection...................................................................................3-103.08 Power Supply Connection to SC-11 Standoff Control ...................................3-113.09 Power Supply Connection to Alternate Standoff Control ............................... 3-123.10 Automation Interface PC Board Set-up ........................................................3-143.11 Optional Remote Current Control Harness Installation.................................. 3-15

SECTION 4: OPERATION ......................................................................................................... 4-1

4.01 Product Features .......................................................................................... 4-14.02 Preparations For Operating ........................................................................... 4-24.03 Selection, Inspection and Replacement of Consumable Torch Parts ............. 4-64.04 Cut Quality ................................................................................................... 4-84.05 General Cutting Information .......................................................................... 4-94.06 Torch Operation ........................................................................................... 4-104.07 Cutting Parameters ......................................................................................4-124.08 Cutting Specifications .................................................................................. 4-134.09 Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed Tip .................. 4-144.10 Cutting Speed Charts: Stainless Steel, SL100 Torch with Exposed Tip ........4-154.11 Cutting Speed Charts: Aluminum, SL100 Torch with Exposed Tip ................ 4-164.12 Cutting Speed Charts: Mild Steel, SL100 Torch with Shielded Tip ................ 4-174.13 Cutting Speed Charts: Stainless Steel, SL100 Torch with Shielded Tip ........4-184.14 Cutting Speed Charts: Aluminum, SL100 Torch with Shielded Tip ................ 4-194.15 Operator's Custom Cutting Speed Charts .................................................... 4-20

TABLE OF CONTENTS (continued)SECTION 5:

SERVICE .......................................................................................................................... 5-1

5.01 General Maintenance .................................................................................... 5-15.02 Common Faults ............................................................................................ 5-55.03 Basic Troubleshooting ................................................................................... 5-65.04 Advanced Troubleshooting Guide - General Information ............................... 5-115.05 Main Input and Internal Power Problems ...................................................... 5-135.06 Pilot Arc Problems....................................................................................... 5-195.07 Main Arc Problems ......................................................................................5-245.08 Test Procedures ........................................................................................... 5-255.09 Power Supply Major External Parts Replacement ........................................ 5-315.10 Front Panel Parts Replacement ....................................................................5-335.11 Left Side Internal Parts Replacement .......................................................... 5-355.12 Right Side Internal Parts Replacement ........................................................5-42

SECTION 6:PARTS LISTS ................................................................................................................... 6-1

6.01 Introduction ................................................................................................... 6-16.02 Ordering Information ..................................................................................... 6-16.03 Complete Power Supply Replacement .......................................................... 6-16.04 Power Supply Basic Replacement Parts ....................................................... 6-26.05 Power Supply Options and Accessories ....................................................... 6-26.06 Power Supply Major External Replacement Parts ......................................... 6-36.07 Power Supply Front Panel Replacement Parts ............................................. 6-46.08 Rear Panel Replacement Parts .................................................................... 6-56.09 Power Supply Left Side Internal Replacement Parts .................................... 6-66.10 Right Side Internal Replacement Parts ........................................................ 6-86.11 Torch Replacement Parts .............................................................................6-106.12 Torch Replacement Parts .............................................................................6-126.13 Torch Consumables ..................................................................................... 6-146.14 Torch Spare Parts Kits ................................................................................. 6-146.15 Complete Torch Assembly Replacement ...................................................... 6-166.16 Torch Options & Accessories ...................................................................... 6-16

PATENT INFORMATION ...........................................................................................................6-17

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM) .......................................................................................................... A-1

APPENDIX 2: DATA TAG INFORMATION ................................................................................ A-2

APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................. A-3

APPENDIX 4: TORCH PIN - OUT DIAGRAMS .......................................................................... A-4

APPENDIX 5: TORCH CONNECTION DIAGRAMS .................................................................. A-5

APPENDIX 6: CONTROL CABLE PIN - OUT DIAGRAM .......................................................... A-6

APPENDIX 7: INTERFACE PCB SWITCH SETTINGS (MOST COMMON SETTINGS) ............ A-7

TABLE OF CONTENTS

APPENDIX 8: INTERFACE PCB SWITCH SETTINGS (Division Factors 16-24) ....................... A-8

APPENDIX 9: INTERFACE PCB SWITCH SETTINGS (Division Factors 24-30) ....................... A-9

APPENDIX 10: INTERFACE PCB SWITCH SETTINGS (Division Factors 30-33) ................... A-10




APPENDIX 14: AUTOMATION INTERFACE PC BOARD WIRING LAYOUT ............................ A-14

APPENDIX 15: AUTOMATION INTERFACE PC BOARD LAYOUT and TEST POINTS ........... A-15

APPENDIX 16: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TOOEM CNC HARNESS .................................................................................................... A-16

APPENDIX 17: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TOALTERNATE CNC HARNESS.......................................................................................... A-17

APPENDIX 18: MAIN PC BOARD LAYOUT ............................................................................ A-18

APPENDIX 19: MAIN PC BOARD WIRING LAYOUT (208 /230-Volt POWER SUPPLIES) ...... A-20

APPENDIX 20: MAIN PC BOARD WIRING LAYOUT (400-Volt, 415-Volt, 460-Volt,600-Volt POWER SUPPLIES) ......................................................................................... A-21

APPENDIX 21: LOGIC BOARD LAYOUT ................................................................................ A-22

APPENDIX 22: POT / LED BOARD LAYOUT .......................................................................... A-23

APPENDIX 23: OUTPUT BOARD WIRING DIAGRAM ............................................................ A-24

APPENDIX 24: OUTPUT DIODE BOARD LAYOUT ................................................................ A-25

APPENDIX 25: PILOT BOARD LAYOUT ................................................................................. A-26

APPENDIX 26: 28VAC CIRCUIT DIAGRAM ........................................................................... A-27

APPENDIX 27: INPUT DIODE LAYOUT.................................................................................. A-28

APPENDIX 28: 208/230V SYSTEM SCHEMATIC ................................................................... A-30

APPENDIX 29: 208/230V SYSTEM SCHEMATIC ................................................................... A-32

APPENDIX 30: 400 / 415V / 460V SYSTEM SCHEMATIC ..................................................... A-34

APPENDIX 31: 400 / 415V / 460V SYSTEM SCHEMATIC ..................................................... A-36

TABLE OF CONTENTS (continued)

APPENDIX 32: 600V SYSTEM SCHEMATIC........................................................................... A-38

APPENDIX 33: 600V SYSTEM SCHEMATIC........................................................................... A-40

APPENDIX 34: Publication History .......................................................................................... A-42

Global Customer Service Contact Information ..................................................... Inside Rear Cover

Manual 0-4641 1-1 GENERAL INFORMATION

SECTION 1:GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warningsare used to highlight important information. These high-lights are categorized as follows:

NOTE

An operation, procedure, or background informa-tion which requires additional emphasis or is help-ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, maycause damage to the equipment.

WARNING

A procedure which, if not properly followed, maycause injury to the operator or others in the oper-ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OFPLASMA ARC EQUIPMENT CAN BE DAN-GEROUS AND HAZARDOUS TO YOURHEALTH.

Plasma arc cutting produces intense electric andmagnetic emissions that may interfere with theproper function of cardiac pacemakers, hearingaids, or other electronic health equipment. Per-sons who work near plasma arc cutting applica-tions should consult their medical health profes-sional and the manufacturer of the healthequipment to determine whether a hazard exists.

To prevent possible injury, read, understand andfollow all warnings, safety precautions and in-structions before using the equipment. Call 1-603-298-5711 or your local distributor if you have anyquestions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting processcan be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keepyour head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not ad-equate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc de-pend on the kind of metal being used, coatings on themetal, and the different processes. You must be verycareful when cutting or welding any metals which maycontain one or more of the following:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium Manganese Vanadium

• Always read the Material Safety Data Sheets(MSDS) that should be supplied with the materialyou are using. These MSDSs will give you the in-formation regarding the kind and amount of fumesand gases that may be dangerous to your health.

• For information on how to test for fumes and gasesin your workplace, refer to item 1 in Subsection 1.03,Publications in this manual.

• Use special equipment, such as water or down draftcutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vaporsof chlorinated solvents and cleansers. Remove allsources of these vapors.

• This product, when used for welding or cutting,produces fumes or gases which contain chemicalsknown to the State of California to cause birth de-fects and, in some cases, cancer. (California Health& Safety Code Sec. 25249.5 et seq.)

GENERAL INFORMATION 1-2 Manual 0-4641

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process usesand produces high voltage electrical energy. This electric en-ergy can cause severe or fatal shock to the operator or othersin the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself fromthe work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist ordamp.

• Install and maintain equipment according to NEC code,refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any serviceor repairs.

• Read and follow all the instructions in the OperatingManual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or theplasma arc.

• Be sure there is no combustible or flammable material inthe workplace. Any material that cannot be removedmust be protected.

• Ventilate all flammable or explosive vapors from the work-place.

• Do not cut or weld on containers that may have heldcombustibles.

• Provide a fire watch when working in an area where firehazards may exist.

• Hydrogen gas may be formed and trapped under alumi-num workpieces when they are cut underwater or whileusing a water table. DO NOT cut aluminum alloys un-derwater or on a water table unless the hydrogen gascan be eliminated or dissipated. Trapped hydrogen gasthat is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processescan cause noise levels to exceed safe limits. You must protectyour ears from loud noise to prevent permanent loss of hear-ing.

• To protect your hearing from loud noise, wear protectiveear plugs and/or ear muffs. Protect others in the work-place.

• Noise levels should be measured to be sure the decibels(sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 inSubsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. Theplasma arc process produces very bright ultra violet and infrared light. These arc rays will damage your eyes and burn yourskin if you are not properly protected.

• To protect your eyes, always wear a welding helmet orshield. Also always wear safety glasses with side shields,goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protectyour skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Re-place lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Useprotective booths, screens or shields.

• Use the shade of lens as suggested in the following perANSI/ASC Z49.1:

Minimum Protective SuggestedArc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc isclearly seen. Experience has shown that lighterfilters may be used when the arc is hidden by theworkpiece.


1.03 Publications

Refer to the following standards or their latest revisions formore information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR1910, obtainable from the Superintendent of Documents,U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUT-TING, obtainable from the American Welding Society, 550N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING ANDGAS WELDING AND CUTTING, obtainable from the Su-perintendent of Documents, U.S. Government Printing Of-fice, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPA-TION AND EDUCATIONAL EYE AND FACE PROTEC-TION, obtainable from American National Standards Insti-tute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American NationalStandards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OFCUTTING AND WELDING PROCESSES, obtainable fromAmerican National Standards Institute, 1430 Broadway, NewYork, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON-TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-tainable from American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMSFOR WELDING, CUTTING AND ALLIED PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,obtainable from the National Fire Protection Associa-tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-CESSES, obtainable from the National Fire Protection As-sociation, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSEDGASES IN CYLINDERS, obtainable from the CompressedGas Association, 1235 Jefferson Davis Highway, Suite 501,Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDINGAND CUTTING, obtainable from the Canadian StandardsAssociation, Standards Sales, 178 Rexdale Boulevard,Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY ob-tainable from the National Welding Supply Association,1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-MENDED SAFE PRACTICES FOR THE PREPARATIONFOR WELDING AND CUTTING OF CONTAINERS ANDPIPING THAT HAVE HELD HAZARDOUS SUBSTANCES,obtainable from the American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORYPROTECTION, obtainable from American National Stan-dards Institute, 1430 Broadway, New York, NY 10018

1.04 Note, Attention etAvertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement”sont utilisés pour mettre en relief des informations à caractèreimportant. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignementgénéral sur lequel il importe d’insister davantageou qui contribue à l’efficacité de fonctionnementdu système.

ATTENTION

Toute procédure pouvant résulterl’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessuresde l’opérateur ou des autres personnes se trouvantdans la zone de travail en cas de non-respect de laprocédure en question.


1.05 Precautions De SecuriteImportantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DUMATÉRIEL DE SOUDAGE À L’ARC AU JETDE PLASMA PEUVENT PRÉSENTER DESRISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit del’énergie électrique haute tension et des émissionsmagnétique qui peuvent interférer la fonctionpropre d’un “pacemaker” cardiaque, les appareilsauditif, ou autre matériel de santé electronique.Ceux qui travail près d’une application à l’arc aujet de plasma devrait consulter leur membreprofessionel de médication et le manufacturier dematériel de santé pour déterminer s’il existe desrisques de santé.

Il faut communiquer aux opérateurs et au person-nel TOUS les dangers possibles. Afin d’éviter lesblessures possibles, lisez, comprenez et suivez tousles avertissements, toutes les précautions de sécuritéet toutes les consignes avant d’utiliser le matériel.Composez le + 603-298-5711 ou votredistributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasmapeuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration.Gardez votre tête hors de la plume de fumée provenant duchalumeau.

• Utilisez un appareil respiratoire à alimentation en air sil’aération fournie ne permet pas d’éliminer la fumée et lesgaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasmadépendent du genre de métal utilisé, des revêtements setrouvant sur le métal et des différents procédés. Vous devezprendre soin lorsque vous coupez ou soudez tout métalpouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre séléniumbéryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité desmatières (sigle américain “MSDS”); celles-ci devraient êtrefournies avec le matériel que vous utilisez. Les MSDScontiennent des renseignements quant à la quantité et lanature de la fumée et des gaz pouvant poser des dangers desanté.

• Pour des informations sur la manière de tester la fumée etles gaz de votre lieu de travail, consultez l’article 1 et lesdocuments cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupeà débit d’eau ou à courant descendant pour capter la fuméeet les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zoneoù se trouvent des matières ou des gaz combustibles ouexplosifs.

• Le phosgène, un gaz toxique, est généré par la fuméeprovenant des solvants et des produits de nettoyagechlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produitde la fumée ou des gaz pouvant contenir des élémentsreconnu dans L’état de la Californie, qui peuvent causerdes défauts de naissance et le cancer. (La sécurité de santéen Californie et la code sécurité Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédéau jet de plasma requiert et produit de l’énergie électrique hautetension. Cette énergie électrique peut produire des chocs graves,voire mortels, pour l’opérateur et les autres personnes sur lelieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”;portez des gants et des vêtements secs. Isolez-vousde la pièce de travail ou des autres parties du circuitde soudage.

• Réparez ou remplacez toute pièce usée ouendommagée.

• Prenez des soins particuliers lorsque la zone de tra-vail est humide ou moite.

• Montez et maintenez le matériel conformément auCode électrique national des Etats-Unis. (Voir la page5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel deconsignes.


INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scorieschaudes, des étincelles ou de l’arc de plasma. Le procédéà l’arc de plasma produit du métal, des étincelles, desscories chaudes pouvant mettre le feu aux matières com-bustibles ou provoquer l’explosion de fuméesinflammables.

• Soyez certain qu’aucune matière combustible ou in-flammable ne se trouve sur le lieu de travail. Protégeztoute telle matière qu’il est impossible de retirer de lazone de travail.

• Procurez une bonne aération de toutes les fuméesinflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayantpu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dansune zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous lespièces de travail en aluminium lorsqu’elles sont coupéessous l’eau ou sur une table d’eau. NE PAS couper lesalliages en aluminium sous l’eau ou sur une table d’eau àmoins que le gas hydrogène peut s’échapper ou se dissiper.Le gas hydrogène accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vosyeux et brûler votre peau. Le procédé à l’arc de plasma produitune lumière infra-rouge et des rayons ultra-violets très forts.Ces rayons d’arc nuiront à vos yeux et brûleront votre peau sivous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou unécran de soudeur. Portez toujours des lunettes de sécuritémunies de parois latérales ou des lunettes de protection ouune autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteurapproprié pour protéger votre peau contre lesétincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protectionen bon état. Remplacez toute lentille sale oucomportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zonede travail contre les rayons de l’arc en fournissant descabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans lerecommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance SuggeréeCourant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel estobservé clairement. L’experience a démontrer queles filtres moins foncés peuvent être utilisés quandl’arc est caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Lesprocédés de soudage à l’arc de plasma peuvent provoquer desniveaux sonores supérieurs aux limites normalement acceptables.Vous dúez vous protéger les oreilles contre les bruits fortsafin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portezdes tampons protecteurs et/ou des protectionsauriculaires. Protégez également les autres personnesse trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer queles décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester lebruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plusrécentes ayant été faites à celles-ci pour de plus amplesrenseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DEPROTECTION DE LA SANTÉ, 29CFR 1910,disponible auprès du Superintendent of Documents,U.S. Government Printing Office, Washington, D.C.20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DECOUPE ET DE SOUDAGE, disponible auprès de la SociétéAméricaine de Soudage (American Welding Society), 550N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DESOPÉRATIONS DE COUPE ET DE SOUDAGE ÀL’ARC ET AU GAZ, disponible auprès du Superin-tendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402


4. Norme ANSI Z87.1, PRATIQUES SURES POUR LAPROTECTION DES YEUX ET DU VISAGE AU TRA-VAIL ET DANS LES ECOLES, disponible de l’InstitutAméricain des Normes Nationales (American Na-tional Standards Institute), 1430 Broadway, NewYork, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LESCHAUSSURES PROTECTRICES, disponible auprèsde l’American National Standards Institute, 1430Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIESLORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ETDE SOUDAGE, disponible auprès de l’American Na-tional Standards Institute, 1430 Broadway, NewYork, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage(AWS), LE SOUDAGE ET LA COUPE DE CONTENEURSAYANT RENFERMÉ DES PRODUITS COMBUSTIBLES,disponible auprès de la American Welding Society, 550N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protectioncontre les Incendies (NFPA), LES SYSTEMES À GAZAVEC ALIMENTATION EN OXYGENE POUR LESOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS,disponible auprès de la National Fire Protection Associa-tion, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL,disponible auprès de la National Fire Protection Associa-tion, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ETDE SOUDAGE, disponible auprès de la National Fire Pro-tection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUEDES GAZ COMPRIMÉS EN CYLINDRES, disponibleauprès de l’Association des Gaz Comprimés (CompressedGas Association), 1235 Jefferson Davis Highway, Suite501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LESOUDAGE ET LA COUPE, disponible auprès del’Association des Normes Canadiennes, Standards Sales,178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉDU SOUDAGE, disponible auprès de l’AssociationNationale de Fournitures de Soudage (National Weld-ing Supply Association), 1900 Arch Street, Philadel-phia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine deSoudage, RECOMMANDATIONS DE PRATIQUESSURES POUR LA PRÉPARATION À LA COUPE ETAU SOUDAGE DE CONTENEURS ET TUYAUX


AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W.LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American NationalStandards Institute, 1430 Broadway, New York, NY 10018

1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street

West Lebanon, New Hampshire 03784USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation forthe enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro-pean Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unitand date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-ated accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-turing process. This is to ensure the product is safe, when used according to instructions in this manual and relatedindustry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensurethe manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in ourarea of manufacture.

Manufacturers responsible representative: Steve WardOperations DirectorThermadyne EuropeEuropa BuildingChorley N Industrial ParkChorley, Lancashire,England PR6 7BX


1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to theoriginal retail purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of thiswarranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicableperiod stated below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been storedoperated and maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industrypractice, correct such defects by suitable repair or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.

Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanshipwithin the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time ThermalDynamics Corporation will provide instructions on the warranty procedures to be implemented.

Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periodsbegin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.

LIMITED WARRANTY PERIOD

Product Power Supply Components(Parts and Labor)

Torch and Leads(Parts and Labor)

CUTMASTER™ 51 3 Years 1 YearCUTMASTER™ 81 3 Years 1 YearCUTMASTER™ 101 3 Years 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.

2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misusedbased upon industry standards.

In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station.Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequentialdamages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamicswith respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture,sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence,strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon whichliability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of anyThermal Dynamics product.

This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.

Effective January 15, 2004

Manual 0-4641 2-1 INTRODUCTION

2

SECTION 2: SPECIFICATIONS

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynam-ics Automated CutMaster 81 Plasma Cutting System. Servicing of this equipment is restricted to properly trainedpersonnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in thismanual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment willassure the dependable operation for which it was designed.

2.02 Power Supply Specifications

Input Power CableOutput CurrentPower Supply Gas Filtering Ability

Ambient TemperatureIEC

RatingTDC

RatingIEC

RatingTDC

RatingIEC

RatingTDC

RatingDuty CycleCurrent 60A 60A 60A 60A 45A 45ADC Voltage 104V 109V 104V 109V 98V 98VDuty CycleCurrent 60A 60A 60A 60A 45A 45ADC Voltage 104V 104V 104V 104V 98V 98VDuty CycleCurrent 60A 60A 60A 60A 43A 43ADC Voltage 104V 109V 104V 109V 97V 97V

208/230V and 460V Units

400V & 415 V Units

600V Units

Input Power

40° C (104° F)

20 - 60 Amps, Continuously AdjustableParticulates to 20 Microns

CutMaster 81 Power Supply Duty Cycle*

50%

460 VAC (414 - 506 VAC), Three Phase, 60 Hz600 VAC (517 - 632 VAC), Three Phase, 60 hzCable for 208/230 VAC unit includes plug.

400 VAC (360 - 440 VAC), Three Phase, 50 Hz, CE

CutMaster 81 Power Supply Specifications208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

460 VAC (414 - 506 VAC), Single Phase, 60 Hz415 VAC (370 - 440 VAC), Three Phase, 50 Hz, CE

* NOTE: The duty cycle will be reduced if the primary input power (AC)is low or the output voltage (DC) is higher than shown in this chart.

50% 60% 100%

50% 60% 100%

60% 100%

NOTE:

IEC Rating is determined as specified by the International Electro-Technical Commission. These specificationsinclude calculating an output voltage based upon power supply rated current. To facilitate comparison betweenpower supplies, all manufacturers use this output voltage to determine duty cycle.

TDC Rating is determined using an output voltage representative of actual output voltage during cutting with aTDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables, andactual cutting operation.

INTRODUCTION 2-2 Manual 0-4641

2

Power Supply Dimensions & Weight Ventilation Clearance Requirements

A-03572

27.5 in / 696 mm

12.4 in / 315 mm

17.3 in /439 mm

83 lb / 37.6 kg

Art # A-03379

6"150 mm

24"0.6 m

6"150 mm

6"150 mm

2.03 Input Wiring Specifications

Input Power Input Current Input Suggested Sizes (See Notes)Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph

208 50/60 11.8 57 60 6 6230 50/60 11.8 52 60 6 6400 50/60 11.1 16 20 10 10460 60 11.7 27 30 10 10460 60 10.8 16 20 12 12600 60 10.5 10 15 12 12

Line Voltages with Suggested Circuit Protection and Wire SizesBased on National Electric Code and Canadian Electrical Code

CutMaster 81 Input Wiring Requirements

Power Input Current InputVoltage Frequency 3-Ph 3-Ph Fuse (Amps) Wire (mm2)(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

400/415 50 11.1 16 20 4

Input Suggested Sizes (See Notes)

Line Voltages with Suggested Circuit Protection and Wire SizesBased on National Electric Code and Canadian Electric Code

CE CutMaster 81 Input Wiring Specifications

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Cable size is de-rated based on the Duty Cycle of the equipment.

The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installationsrefer to local or national codes.

Cable conductor temperature used is 167° F (75° C).

An energy limiting fuse UL Class RK-1 (examples: BUSS LPS / LPN-RK or Gould-Shawmut AZK-A6K) should beused to minimize damage to Plasma Cutting, Welding or power distribution equipment.

NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.


2

2.04 Power Supply Features

Art # A-04214

Input Power Cord

Gas Inlet Port

Gas Pressure Regulator / Filter Assembly

Gas Pressure Gauge

CPC Connector forThermal Dynamics CNC Controller

Knockout for AlternateCNC Controller Wire Harness

Art # A-04507

Work Cableand Clamp

Handle and Leads Wrap

Torch Leads Receptacle

Control Panel


2

2.05 Power Supply Options and Accessories

Section 6, Parts Lists, provides catalog numbers and ordering information.

A. Single-Stage Air Filter Kit

For use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least0.85 microns. This filter increases performance and improves consumables parts life.

B. Two Stage Air Filter Kit

For use on compressed air shop systems. Filters moisture and contaminants from the air stream to at least 5.0microns. This filter is pre-assembled at the factory and needs only to be installed on the power supply.

C. High Pressure Regulators

High pressure regulators are available. The regulators are used to set the proper compressed air pressure.

NOTE

Regulators should not be installed with In-Line Air Filters.

D. Extended Work Cable with Clamp

As an alternative to the standard 20 ft / 6.1 m work cable & clamp on the power supply, a 50 ft / 15.2 m work cablewith clamp is available.

E. Multi-Purpose Cart

Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility forthe power supply and can also serve as a display cart. Top shelf is 12" / 305 mm x 20" / 508 mm. Steel handle is30" / 762 mm high.

F. Wheel Kit

A kit with easy-rolling wheels, for maximum portability for the power supply.

G. Nylon Dust Cover

Nylon canvas power supply dust cover with water resistant finish, large outer pocket for storing manuals or spareconsumables, and adjustable draw cord for tight fit.


2

2.06 Torch Specifications

Ambient Temperature 104° F / 40° CDuty Cycle (Refer to NOTE) 100% @ 100 Amps @ 400 scfhMaximum Current 100 AmpsVoltage (Vpeak) 500VArc Striking Voltage 7kV

Type of Cooling Combination of Ambient Air and Gas Flow Through Torch

Current Rating Up to 100 Amps, DC, Straight Polarity

Gas (Plasma and Secondary) Compressed Air (ONLY)Operating Pressure (Varies According to Power Supply and Torch Leads Length)

60 - 75 psi4.1 - 5.2 bar

Maximum Input Pressure 125 psi / 8.6 barGas Flow 300 - 500 scfh / 142 - 235 lpm

SL100SV Machine Torch Specifications

Gas Requirements

Torch Leads LengthsNOTE: Operating pressure varies with operating amperage and torch leads length.

Torch duty cycle is greater than power supply duty cycle.

Plasma Power Supply Used With:Thermal Dynamics CutMaster 51, CutMaster 81, CutMaster 101, CutMaster 151

Torch Ratings

25' / 7.6 m, with ATC Connector 35' / 10.6 m, with ATC Connector50' / 15.2 m, with ATC Connector

NOTE

A. Torch Configuration

The standard machine torch has a positioning tube with rack & pinch block assembly.

Art # A-07402

1.75" / 44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" /16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm2.875” / 73 mm


2

B. Torch Connector Dimensions

8.5" / 216 mm

5.375" / 137 mm

1.9" / 50 mm

Art # A-04056

C. Torch Parts

Start Cartridge, Electrode, Tip, Shield Cup Body, Shield Cap

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 vdc circuit rating

E. Direct Contact Hazard

For exposed tip the recommended standoff is 3/16 inches / 4.7 mm.

2.07 Torch Options and Accessories

These items can adapt a standard system to a particular application or further enhance performance (refer to Section 6for ordering information).

• Spare Parts Kits - Various kits containing replacement consumable torch parts.

• Pinion Assembly (for machine torches)

• Leather Leads Covers


2

2.08 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electricallyconductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. Themetal to be cut or removed is melted by the heat of the arc and then blown away.

In a Plasma Cutting Torch a cool gas enters Zone B, where a pilot arc between the electrode and the torch tip heatsand ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas inZone C.

��

��

��

��

A-00002

Workpiece

PowerSupply

+

_

C

B

A

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of heat toa small area. The stiff, constricted plasma arc is shown in Zone C. Direct current (DC) straight polarity is used forplasma cutting, as shown in the illustration.

Zone A channels a secondary gas that cools the torch. This gas also assists the high velocity plasma gas in blowingthe molten metal out of the cut allowing for a fast, slag - free cut.

B. Gas Distribution

The single gas used is internally split into plasma and secondary gases.

The plasma gas flows into the torch through the negative lead, through the start cartridge, around the electrode,and out through the tip orifice.

The secondary gas flows down around the outside of the torch start cartridge, and out between the tip and shieldcup around the plasma arc.


2

C. Pilot Arc

When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates apath for the main arc to transfer to the work.

D. Main Cutting Arc

DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through thetorch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilotwire.

E. Parts - In - Place (PIP)

The torch leads include a ‘Parts - In - Place’ (PIP) circuit. When the torch shield cup is properly installed, it closesa switch. The torch will not operate if this switch is open.

A-03504

PIP Switch Shield CupTo ControlCable Wiring

Parts - In - Place Circuit Diagram

Manual 0-4641 3-1 INSTALLATION

3

SECTION 3: INSTALLATION

3.01 Unpacking

1. Use the packing lists to identify and account for each item.

2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shippingcompany before proceeding with the installation.

3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the informationblock at the front of this manual.

3.02 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.

WARNINGS

Do not touch live electrical parts.

Disconnect input power cord before moving unit.

FALLING EQUIPMENT can cause serious personal injury and can damage equipment.

HANDLE is not for mechanical lifting.

• Only persons of adequate physical strength should lift the unit.

• Lift unit by the handle, using two hands. Do not use straps for lifting.

• Use optional wheel kit, cart or similar device of adequate capacity to move unit.

• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

INSTALLATION 3-2 Manual 0-4641

3

3.03 Primary Input Power Connections

CAUTION

Check your power source for correct voltage before plugging in or connecting the unit. The primary powersource, fuse, and any extension cords used must conform to local electrical code and the recommended circuitprotection and wiring requirements as specified in Section 2.03.

A. Connections to 208 / 230-Volt Power

The 208 / 230-Volt power supply includes a factory-installed input power cable and plug.

1. Check your power source for correct voltage before plugging in the unit.

2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuitprotection and wiring requirements (refer to table in Section 2.03).

B. Connections to 400-Volt, 415-Volt, 460-Volt, or 600-Volt Three-Phase Power

These Power Supplies are equipped with a four-conductor input power cable for three-phase input power. The 460-Volt PowerSupplies will accept 460-VAC, Single-Phase input power with a change of input power cable.

1. Check your power source for correct voltage before plugging in the unit.

2. The input cable's outer covering is stripped back at the factory to expose the individual wires at the free end of the cable.

3. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuitprotection and wiring requirements (refer to table in Section 2 ). All the input cable wires must be connected forthree-phase operation.

• Green / Yellow wire to Ground.

• Remaining wires to L1, L2, L3 input.



3

C. Connections to 460-Volt Single - Phase Power

The 460-Volt Power Supplies will accept 460-VAC, Single-Phase input power with a change of input power cable.

1. Remove the Power Supply cover per section 5.09-A.

2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.

3. Loosen the through-hole protector on the back panel of the power supply. Pull the original power cable out of the powersupply.

4. Pass a customer-supplied, three-conductor input power cable through the access opening in the back panel of the powersupply. Refer to Section 2 for power cable specifications.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuitprotection and wiring requirements (refer to table in Section 2.03).

5. Strip back the insulation on the individual wires.

6. Connect to main input contactor as follows:

• Line 1 wire to terminal L1.

• Line 3 wire to terminal L3.

7. Connect the ground wire to Ground (Earth). The Ground wire connection requires a ring terminal.

8. Tighten the through-hole protector to secure the power cable.

A-03041

L1

L3

Ground Wirewith RingTerminal

Main Input Contactor

Input Cable

L1 L2 L3

Input Power Connections, 460 VAC, Single-Phase

9. Replace the Power Supply cover.



3

3.04 Gas Connections

A. Connecting Gas Supply to Unit

Use only compressed air with this power supply.

An in-line pneumatic dryer & evaporator type air filter, capable of filtering to at least 5 microns, is required when using air from acompressor. This type filter will insure that moisture, oil, dirt, chips, rust particles, and other contaminants from the supply hosedo not enter the torch. For highly automated applications, a refrigerated drier may be used.

The connection is the same for compressed air from a compressor from high pressure cylinders. Refer to subsection 3.4-B or 3.4-C if an additional air line filter is to be installed.

1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. Other fittings can beused.

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do not useTeflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Art # A-02999

Hose Clamp

1/4 NPT to 1/4"(6mm) Fitting

Regulator/FilterAssembly

Inlet Port

Gas SupplyHose

Bowl

Air Connection to Inlet Port


3

B. Optional Air Filters

1. Connect the Filter as illustrated. Use only Synflex or equivalent grade hose. The illustrations show typical fittings as anexample.

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not useTeflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in thetorch. Connect as follows:

Art # A-03000


Inlet Port

Bowl

1/4 NPT Hose Fitting

1/4" (6 mm) Gas Supply Hose

Hose Clamp

Art # A-03004


HoseClamp

1/4 NPT Hose Fitting

1/4" (6 mm) Gas Supply Hose)

2-Stage FilterInlet Port (IN)

Outlet Port(OUT)

Regulator Inlet Port

Two Stage Filter

Assembly

Optional Single-Stage Filter Installation Optional Two-Stage Filter Installation


3

D. Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regula-tors.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly openeach cylinder valve to blow out any dust which may be present.

3. The cylinder must be equipped with an adjustable high-pressure regulator capable of outlet pressures up to 100 psi (6.9 bar)maximum and flows of at least 500 scfh (236 lpm).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.

Supply hose must be at least 1/4 inch (6 mm) I.D.

For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not useTeflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.


3

3.05 Torch Connections

If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100 Torch (with ATCconnector) to this power supply. Maximum torch leads length is 50 feet / 15.2 m.

WARNING

Disconnect primary power at the source before connecting the torch.

1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into thefemale receptacle. The connectors should push together with a small amount of pressure.

2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pullthe connection together. Do not use tools to secure the connection.

3. The system is ready for operation.

Torch Leads

Art # A-06755

1

2

ATC Male Connector

ATC Female Receptacle (Panel Mounted)


3

Connecting the Torch to the Power Supply

B. Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON (up) position.

2. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position.

3. Place a welding filter lens in front of the torch and turn on the air. Any oil or moisture in the air will be visible on the lens.Do not start an arc!

Art # A-03592

A

20

40

601 2


3

3.06 Torch Installation

WARNING

Disconnect primary power at the source before disassembling the torch or torch leads.

The machine torch includes a positioning tube with rack and pinch block assembly.

1. Mount the torch assembly on the cutting table.

2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece.

A-02585

Workpiece

Square

Pinch BlockAssembly

Machine Torch Set-Up

3. The proper torch parts (shield cup body, shield cap, tip, start cartridge, and electrode) must be installed for the type ofoperation. Refer to Section 3.07, Torch Parts Selection for details.


3

3.07 Torch Parts Selection

1. Check the torch for proper consumable parts. The parts supplied in the torch may not be correct for the operator's chosenamperage level. The torch parts must correspond with the type of operation.

Art # A-04173

Electrode

Start Cartridge

Tip

Ohmic Clip (If Installed)

Torch Head

Shield Cup Body

Shield CapDeflector


3

3.08 Power Supply Connection to SC-11 Standoff Control

The power supply includes an Automation Interface PC Board connected to a CPC connector on the power supply rear panel.For connection to the Thermal Dynamics SC-11 Standoff Control, align and connect the cable from the Standoff Control to theCPC connector. Check for a secure connection.


Art # A-04075

Connector for SC-11Standoff Control / CNC


3

3.09 Power Supply Connection to Alternate Standoff Control

The Power Supply rear panel includes a knockout to accept wiring between the Automation Interface PC Board and alternate CNCcontrols. The Automation Interface PC board includes a terminal strip for connection to alternate CNC controls.

To connect an alternate CNC Control to the Power Supply:

1. Remove the Power Supply Cover.

2. Carefully open the lower knockout (below the factory-installed CNC connector) on the Power Supply rear panel.


Art # A-04178

Knockout for AlternateCNC Controller

3. Install a customer-supplied through-hole protector ('Strain Relief') in the lower knockout hole.

4. Route the wire harness from the alternate CNC Control through the through-hole protector.


3

5. Connect the wire harness from the alternate CNC Control to the 20-position terminal strip (labeled 'J2') on the AutomationInterface PC Board. Refer to the illustration.

a. For divided voltage output, connect to terminals J2-11 (negative) and J2-9 (positive) on the Interface PC Board..

b. For raw arc voltage, connect to terminals E2 (positive) and E1 (negative) on the Output Power PC Board.

NOTE

There is no need to disconnect the factory-installed wire harness from the J4 terminal strip.

39 5 4 12678101319 15 14 111216171820

Art # A-04149

Torc

h Switc

h

(Pos

itive)

Torc

h Switc

h (N

egat

ive)

OK to M

ove

OK to M

ove

Divide

d Out

put (

Positiv

e)

Divide

d Out

put (

Negat

ive)

Logic

Com

mon

Open

Open

Open

Open

Open

Open

Open

Open

Arc Vo

lts -

Positiv

e (P

ropr

ietar

y)

Arc Vo

lts N

egat

ive -

(Pro

priet

ary)

Remot

e Cur

rent

Con

trol (

Option

al)

Remot

e Cur

rent

Con

trol (

Option

al)

Remot

e Cur

rent

Con

trol (

Option

al)

To Main PC Board Terminal J27-3



Installed only with Optional Remote Current Control

Terminal Block J2

E2 (+)E1(-)

Automation Interface PC Board

Output Power PC Board

Raw Arc Voltage Connection Points

Alternate CNC Controller Connections to Automation Interface Board

6. Tighten the through-hole protector ('strain relief') to secure the CNC cable to the power supply.


3

3.10 Automation Interface PC Board Set-up

The Automation Interface PC board includes switches that must be set to adapt the Interface Board to the automation systembeing used.

NOTE

The switches are factory-set for the Thermal Dynamics SC-11 Standoff Control.

For operation with any other CNC equipment, refer to the CNC system documents to determine the division factor the CNCsystem requires. Proceed as follows:

1. Set the interface control board switches as indicated in the appropriate chart in the Appendix pages. The division factorsare listed in the right-hand column of each chart.


Art # A-03902

Pilot PCBoard

Output PowerPC Board


Art # A-03757

Switches

8 7 6 5 4 3 2 1

2. Re-install the Power Supply cover.


3

3.11 Optional Remote Current Control Harness Installation

1. Locate the power supply Pot/LED Board just inside the power supply front panel.

Art # A-03964

Pot / LED Board

2. Disconnect and remove the wire harness between the Pot/LED Board and receptacle J22 on the Main PC Board. Keep theharness for possible future use.

3. The kit includes a wire harness with 3 connectors. Install the harness as follows:

To Pot/LED BoardReceptacle J14

To Automation Interface BoardReceptacle J3

To Main PC BoardReceptacle J27

Connector Plugs

Art # A-03945

4. Ensure that the wire harness will not interfere with the fit of the power supply cover against the top edge of the powersupply center chassis. Use wire ties as needed to secure the wire harness.

NOTE

Installation of this harness disables the output current control (A) on the front panel of the power supply. Use the CNCcontroller to control the output current of the power supply.

5. Re-install the Power Supply cover.


3 This Page Left Blank

Manual 0-4641 4-1 OPERATION

4

SECTION 4: OPERATION

4.01 Product Features

A. Power Supply Front Panel Controls and Indicators

(A) Output Current Control

Sets the desired output current. At output settingsover 40 Amps, the power supply automatically re-duces output current to 40 Amps if the torch tiptouches the workpiece.

ON / OFF Switch

Controls input power to the power supply.

is ON, is OFF.

RUN / RAPID AUTO RESTART / SET Switch

RUN (up) position is for general torch operation.

RAPID AUTO RESTART (middle) position is for an uninterrupted restart, when cutting

expanded metal or in trimming operations.

SET (down) position is for setting gas pressure and purging lines.

AC Indicator

Steady light indicates power supply is ready foroperation. Blinking light indicates unit is in pro-tective interlock mode. Shut unit off, shut off ordisconnect input power, correct the fault, and re-start the unit. Refer to Section 5 for details.

TEMP Indicator

Indicator is normally OFF. Indicator is ONwhen internal temperature exceeds normallimits. Shut unit OFF; let the unit cool beforecontinuing operation.

GAS Indicator

Indicator is ON when minimum input gaspressure for power supply operation ispresent. Minimum pressure for power sup-ply operation is not sufficient for torch op-eration.

DC Indicator

Indicator is ON when DC output circuit isactive.

Art # A-03743

A

20

40

60

OPERATION 4-2 Manual 0-4641

4

4.02 Preparations For Operating

Perform the following steps at the start of each operating session:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch andleads assemblies.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type ofoperation, and with the amperage output of this Power Supply (80 amps maximum).

B. Torch Connection

Check that the torch is properly connected. Only Thermal Dynamics model SL100 Torches may be connected tothis Power Supply.

C. Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets the power re-quirements for the unit per Section 2, Specifications.


D. Gas Selection

Ensure compressed air source meets requirements (refer to Section 3.4). Check connections and turn gas supply on.

Place the ON - OFF Switch on the Power Supply to the ON position. If the Run - Rapid Auto Restart - Set switch is in SETposition, gas will flow. If the switch is in RUN or Rapid Auto Restart position there will be no gas flow.

E. Connect Work Cable

Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the mainpart of the workpiece; do not connect to the part to be cut off.

Art # A-04509


4

F. Power On

Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator

turns on if there is sufficient gas pressure for power supply operation.

NOTE

Minimum pressure for power supply operation is lower than minimum for torch operation.

Art # A-03594

A

20

40

60


4

G. Set Operating Pressure

1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow.

Art # A-03592

A

20

40

601 2

2. Adjust gas pressure per the settings chart.

Leads Length

Up to 25' (7.6 m)

Over 25' (7.6 m)

40A Cutting 65 psi4.5 bar

70 psi4.8 bar

60A Cutting 70 psi4.8 bar

75 psi5.2 bar

CutMaster 81 Gas Pressure Settings

Art # A-03581

65 - 80 psi / 4.5- 5.5 bar Pressure Control Knob /

Bouton De Contrôle de Pression


4

H. Select Current Output Level

1. Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Gas flow stops.

2. Set the current output level, up to 80 amps for standoff cutting. At output settings higher than 40 amps, thepower supply automatically reduces output current to 40 amps if the torch tip contacts the workpiece.

Art # A-03593

A

20

40

60

1

2

I. Cutting Operation

When the torch leaves the workpiece during cutting operations with the RUN / Rapid Auto Restart / SET switch in the RUN(up) position, there is a brief delay in restarting the pilot arc. With the switch in the 'Rapid Auto Restart' (middle) position,when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arccontacts the workpiece. Use the 'Rapid Auto Restart' position when cutting expanded metal or gratings, or in trimmingoperations when an uninterrupted restart is desired.

J. Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill.

Output current setting or cutting speeds may be reduced to allow slower cutting while still producing cuts of excellent quality.

K. Postflow

De-activate the start signal (provided by the CNC Control) to stop the cutting arc. Gas continues to flow for approximately 6seconds. During post - flow, if the user activates start signal, the pilot arc starts. The main arc transfers to the workpiece if thetorch tip is within transfer distance to the workpiece.


4

4.03 Selection, Inspection and Replacement of Consumable Torch Parts

The type of operation to be done determines the torch parts to be used. Change the torch parts for a different operation asfollows:

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

Art # A-04173

Electrode

Start Cartridge

Tip

Ohmic Clip (If Installed)

Torch Head

Shield Cup Body

Shield CapDeflector

Consumable Parts

1. Unscrew and remove the shield cup assembly from the torch head. Inspect the cup for damage. Wipe it clean or replace ifdamaged.

NOTES

The shield cup holds the tip and start cartridge in place.

Slag built up on the shield cup that cannot be removed may affect the performance of the system.


4

2. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tipif necessary.

Good Tip Worn Tip

A-03406

Tip Wear

3. Remove the start cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower endfitting for free motion. Replace if necessary.

Art # A-07168

Spring-Loaded Cylinder at Full Compression

Spring-Loaded Cylinder at Full Extension

1/8” (3 mm)

4. Pull the Electrode straight out of the Torch Head. Check the end of the electrode for excessive wear. Replace theelectrode if wear is greater than 0.062" / 1.5 mm or if the wear is excessively off-center. Refer to the following figure.

Electrode WearArt # A-04057

0.062" (1.5 mm)

Electrode Wear

5. Reinstall the Electrode by pushing it straight into the torch head until it clicks.

6. Reinstall the start cartridge and tip into the torch head.

7. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threadsbefore proceeding.

NOTE

When the shield cup is properly installed, there is a slight gap between the shield cup and the torch head. Gas ventsthrough this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing theshield cup against the torch head can damage components.


4

4.04 Cut Quality

NOTES

Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cuttingspeed, gas pressures, and operator ability.

Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may be major factorswhen the surface will be welded after cutting. Dross - free cutting is important when finish cut quality is desired to avoid asecondary cleaning operation. The following cut quality characteristics are illustrated in the following figure:

Kerf WidthCut SurfaceBevel Angle

Top EdgeRounding

Cut SurfaceDrag Lines

DrossBuild-Up

TopSpatter

A-00007

Cut Quality Characteristics

A. Cut Surface

The desired or specified condition (smooth or rough) of the face of the cut.

B. Nitride Build - Up

Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream. These buildups maycreate difficulties if the material is to be welded after the cutting process.

C. Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectlyperpendicular cut would result in a 0° bevel angle.

D. Top - Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

E. Bottom Dross Buildup

Molten material which is not blown out of the cut area and resolidifies on the plate. Excessive dross may requiresecondary cleanup operations after cutting.

F. Kerf Width

The width of the cut (or the width of material removed during the cut).

G. Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose orifice hasbecome elongated.


4

4.05 General Cutting Information

WARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equippedwith proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contactwith the workpiece while the torch is activated.

CAUTION

Sparks from the cutting process can damage coated, painted, and other surfaces such as glass, plastic and metal.

NOTE

Handle torch leads with care and protect them from damage.

A. Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tiprather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

B. Torch Standoff

Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well asshield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff will generally result ina more square cut.

C. Edge Starting

For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) theedge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pauseat the edge and force the arc to “reach” for the edge of the metal. Establish the cutting arc as quickly as possible.

D. Direction of Cut

In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirleffect results in one side of a cut being more square than the other. Viewed along the direction of travel, the rightside of the cut is more square than the left.

Right SideCut Angle

Left SideCut Angle

A-00512

Scrap

Clockwise

Counter-Clockwise

Art # A-04182

Workpiece

Scrap

Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle.To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.


4

E. Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”.Dross present on top of the plate is normally caused by too great a torch to plate distance. “Top dross” is nor-mally very easy to remove and can often be wiped off with a welding glove. “Slow speed dross” is normallypresent on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to thecut edge, and can be easily scraped off. “High speed dross” usually forms a narrow bead along the bottom of thecut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce thecutting speed to produce “slow speed dross”. Any resultant cleanup can be accomplished by scraping, notgrinding.

4.06 Torch Operation

A. Cutting

1. Use a square to check that the torch is perpendicular to the workpiece to obtain a clean, vertical cut.

A-02585

Workpiece

Square

Pinch BlockAssembly

Checking Alignment

2. To start a cut at the plate edge, position the center of the torch along the edge of the plate.


4

B. Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of thefollowing:

1. Straight Arc

A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cutusing air plasma on stainless or aluminum.

2. Leading Arc

The leading arc is directed in the same direction as torch travel. A five degree leading arc is generally recom-mended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel.

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

Machine Torch Operation

For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arccolumn produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side toside in search of metal for transfer.

Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down thetravel speed will result in a squarer cut.


4

C. Piercing With Machine Torch

To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above theplate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow backonto the front end of the torch.

When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arcpenetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended 1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible.Spraying or dipping the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

4.07 Cutting Parameters

Cutting speed depends on material, thickness, and other factors. These may have an impact on system performance:

• Torch parts wear

• Air quality

• Line voltage fluctuations

• Torch standoff height

• Proper work cable connection


4

Cut Quality on Various Materials andThicknesses

The following table defines the cut quality on various mate-rials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of CutThickness Material Gas Characteristics

Gageto

3/4 inch( 19 mm )

Good - Excellent

Good

Good

Carbon Steel

Stainless

Aluminum

Air

Air

Air

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip orifice diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tiporifice diameter), some dross (easily removed), medium -smooth cut surface, slight top edge rounding.

4.08 Cutting Specifications

Cutting RangeMaterial Most Metals

Up to 3/4 inch - 19 mmSpeed 11 ipm / 0.28 mpm

Pierce RatingMaterial Carbon Steel

Thickness 3/8 inch - 9.5 mmTransfer Distance 3/8 inch - 9.5 mmGas Requirement

Type Gas Air

Operating Pressure 65 psi / 4.5 bar

Max Input Pressure 125 psi / 8.6 barCutting & Gouging

Total Flow 350 scfh / 165 lpm

Torch Specifications ForCutMaster 81 Power Supplies


4

4.09 Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed Tip

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, increase pressure by 5 psi / 0.34 bar.

This information represents realistic expectations using recommended practices and well - maintained systems.Actual speeds may vary up to 50% from those shown.

Electrode Start Cartridge Tip Shield Cup Body Shield Cap, Deflector 9-8215 9-8213 9-8237 9-8243

Art # A-04203

Torch: SL100 with Exposed Tip and DeflectorPower Supply: CutMaster 81 Automated

Tip Current PlasmaPress.*

Pierce Time

Arc voltage

In GA mm Cat. # Amps PSI In mm SEC Volts in mm IPM mm/min0.036 20 0.91 8-8208 40 65 0.188 4.8 0.00 96 0.19 4.80 341 8661.40.051 1.30 8-8208 40 65 0.188 4.8 0.00 97 0.19 4.80 300 76200.060 16 1.52 8-8208 40 65 0.188 4.8 0.10 98 0.19 4.80 265 67310.075 14 1.91 8-8208 40 65 0.188 4.8 0.30 100 0.19 4.80 190 48260.135 10 3.43 8-8208 40 65 0.188 4.8 0.40 101 0.19 4.80 120 30480.141 3.58 8-8208 40 65 0.188 4.8 0.50 102 0.19 4.80 112 2844.80.188 4.78 8-8208 40 65 0.188 4.8 0.60 107 0.19 4.80 60 15240.250 6.35 8-8208 40 65 0.188 4.8 1.00 111 0.19 4.80 40 10160.375 9.53 8-8208 40 65 NR NR NR 119 0.19 4.80 19.7 500.380.500 12.70 8-8208 40 65 NR NR NR 123 0.19 4.80 11.1 281.940.625 15.88 8-8208 40 65 NR NR NR 127 0.19 4.80 6 152.40.060 16 1.57 9-8210 60 70 0.188 4.8 0.00 110 0.19 4.80 293 7442.20.075 14 1.91 9-8210 60 70 0.188 4.8 0.10 110 0.19 4.80 288 7315.20.120 11 3.05 9-8210 60 70 0.188 4.8 0.10 111 0.19 4.80 273 6934.20.135 10 3.43 9-8210 60 70 0.188 4.8 0.10 111 0.19 4.80 215 54610.141 3.58 9-8210 60 70 0.188 4.8 0.15 112 0.19 4.80 177.6 4511.040.188 4.78 9-8210 60 70 0.188 4.8 0.20 114 0.19 4.80 137 3479.80.250 6.35 9-8210 60 70 0.188 4.8 0.30 116 0.19 4.80 82.4 2092.960.375 9.53 9-8210 60 70 0.188 4.8 0.50 118 0.19 4.80 42.4 1076.960.500 12.70 9-8210 60 70 0.188 4.8 0.75 119 0.19 4.80 26.3 668.020.625 15.88 9-8210 60 70 NR NR NR 127 0.19 4.80 17.4 441.960.750 19.05 9-8210 60 70 NR NR NR 126 0.19 4.80 16 406.41.000 25.40 9-8210 60 70 NR NR NR 128 0.19 4.80 12 304.8

Material: Mild SteelTable: DryGas: Compressed Air

RecommendedTravel Speed

Stand-offHeightPierce HeightMaterial thickness


4

4.10 Cutting Speed Charts: Stainless Steel, SL100 Torch with Exposed Tip

NOTES

*Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, increase pressure by 5 psi / 0.34 bar.



Art # A-04203

Table: DryGas: Compressed Air

Material thickness Tip Current PlasmaPress.*

Pierce Time

Arc voltage

Stand-offHeight


In GA mm Cat. # Amps PSI In mm SEC Volts in mm IPM mm/min0.038 20 0.95 8-8208 40 65 0.188 4.8 0.00 103 0.19 4.80 357 9067.80.050 18 1.27 8-8208 40 65 0.188 4.8 0.00 104 0.19 4.80 287 7289.80.063 16 1.60 8-8208 40 65 0.188 4.8 0.10 104 0.19 4.80 244 6197.60.078 14 1.98 8-8208 40 65 0.188 4.8 0.30 105 0.19 4.80 125 31750.135 3.43 8-8208 40 65 0.188 4.8 0.40 105 0.19 4.80 106 2692.40.141 10 3.58 8-8208 40 65 0.188 4.8 0.50 106 0.19 4.80 104 2641.60.188 4.78 8-8208 40 65 0.188 4.8 0.60 106 0.19 4.80 75 19050.250 6.35 8-8208 40 65 0.188 4.8 1.00 109 0.19 4.80 46.6 1183.640.375 9.53 8-8208 40 65 NR NR NR 109 0.19 4.80 31.5 800.10.500 12.70 8-8208 40 65 NR NR NR 112 0.19 4.80 17.4 441.960.625 15.88 8-8208 40 65 NR NR NR 114 0.19 4.80 10 2540.063 16 1.57 9-8210 60 70 0.188 4.8 0.00 107 0.19 4.80 177 4495.80.078 14 1.98 9-8210 60 70 0.188 4.8 0.10 108 0.19 4.80 169 4292.60.125 11 3.18 9-8210 60 70 0.188 4.8 0.10 109 0.19 4.80 140 35560.135 3.43 9-8210 60 70 0.188 4.8 0.10 110 0.19 4.80 117 2971.80.141 10 3.58 9-8210 60 70 0.188 4.8 0.15 111 0.19 4.80 103 2616.20.188 4.78 9-8210 60 70 0.188 4.8 0.20 112 0.19 4.80 90 22860.250 6.35 9-8210 60 70 0.188 4.8 0.30 113 0.19 4.80 68.8 1747.520.375 9.53 9-8210 60 70 0.188 4.8 0.50 115 0.19 4.80 35 8890.500 12.70 9-8210 60 70 0.188 4.8 0.75 121 0.19 4.80 21.3 541.020.625 15.88 9-8210 60 70 NR NR NR 127 0.19 4.80 15.9 403.860.750 19.05 9-8210 60 70 NR NR NR 131 0.19 4.80 12.5 317.51.000 25.40 9-8210 60 70 NR NR NR 135 0.19 4.80 6 152.4

Material: Stainless Steel

Pierce Height

Torch: SL100 with Exposed Tip and DeflectorPower Supply: CutMaster 81 Automated


4

4.11 Cutting Speed Charts: Aluminum, SL100 Torch with Exposed Tip

NOTES




Art # A-04203

Tip Current PlasmaPress.*

Pierce Time

Arc voltage

In GA mm Cat. # Amps PSI In mm SEC Volts in mm IPM mm/min0.040 20 1.02 8-8208 40 65 0.188 4.8 0.00 94 0.19 4.80 440 111760.052 18 1.32 8-8208 40 65 0.188 4.8 0.00 96 0.19 4.80 440 111760.064 16 1.63 8-8208 40 65 0.188 4.8 0.10 98 0.19 4.80 440 111760.079 14 2.01 8-8208 40 65 0.188 4.8 0.30 102 0.19 4.80 297 7543.80.125 3.18 8-8208 40 65 0.188 4.8 0.35 106 0.19 4.80 145.6 3698.240.135 3.43 8-8208 40 65 0.188 4.8 0.40 108 0.19 4.80 135 34290.187 4.75 8-8208 40 65 0.188 4.8 0.60 112 0.19 4.80 98 2489.20.250 6.35 8-8208 40 65 0.188 4.8 1.00 115 0.19 4.80 50.4 1280.160.375 9.53 8-8208 40 65 NR NR NR 122 0.19 4.80 22 558.80.500 12.70 8-8208 40 65 NR NR NR 126 0.19 4.80 13.5 342.90.625 15.88 8-8208 40 65 NR NR NR 130 0.19 4.80 8 203.20.034 22 1.57 9-8210 60 70 0.2 5.1 0.00 95 0.19 4.80 440 111760.079 14 2.01 9-8210 60 70 0.2 5.1 0.10 98 0.19 4.80 440 111760.125 3.18 9-8210 60 70 0.2 5.1 0.10 103 0.19 4.80 440 111760.135 3.43 9-8210 60 70 0.2 5.1 0.10 108 0.19 4.80 340 86360.141 3.58 9-8210 60 70 0.2 5.1 0.15 111 0.19 4.80 275 69850.188 4.78 9-8210 60 70 0.2 5.1 0.20 115 0.19 4.80 170 43180.250 6.35 9-8210 60 70 0.2 5.1 0.30 119 0.19 4.80 94.4 2397.760.375 9.53 9-8210 60 70 0.2 5.1 0.50 122 0.19 4.80 57.4 1457.960.500 12.70 9-8210 60 70 0.2 5.1 0.75 128 0.19 4.80 34.4 873.760.625 15.88 9-8210 60 70 NR NR NR 131 0.19 4.80 23 584.20.750 19.05 9-8210 60 70 NR NR NR 134 0.19 4.80 17.6 447.041.000 25.40 9-8210 60 70 NR NR NR 140 0.19 4.80 8 203.2

Material: AluminumTorch: SL100 with Exposed TipPower Supply: CutMaster 81 Automated


Pierce HeightMaterial thickness Stand-offHeight



4

4.12 Cutting Speed Charts: Mild Steel, SL100 Torch with Shielded Tip

NOTES



Electrode Start Cartridge Tip Shield Cup Body Shield Cap, Machine 9-8215 9-8213 9-8237 Art # A-04204

TorchTip

ShieldCap Current Plasma

Press.*Pierce Time

Arc voltage

In GA mm Cat. # Cat. # Amps PSI In mm SEC Volts in mm IPM mm/min0.036 20 0.9144 8-8208 9-8245 40 65 1.88 4.8 0.00 102 0.19 4.80 170 43180.051 1.30 8-8208 9-8245 40 65 1.88 4.8 0.00 103 0.19 4.80 148 3759.20.060 16 1.52 8-8208 9-8245 40 65 1.88 4.8 0.10 104 0.19 4.80 133 3378.20.075 14 1.91 8-8208 9-8245 40 65 1.88 4.8 0.30 106 0.19 4.80 95 24130.135 10 3.43 8-8208 9-8245 40 65 1.88 4.8 0.40 110 0.19 4.80 65 16510.188 4.78 8-8208 9-8245 40 65 1.88 4.8 0.60 113 0.19 4.80 30 7620.250 6.35 8-8208 9-8245 40 65 1.88 4.8 1.00 117 0.19 4.80 23 584.20.375 9.53 8-8208 9-8245 40 65 NR NR NR 126 0.19 4.80 10 2540.500 12.70 8-8208 9-8245 40 65 NR NR NR 122 0.19 4.80 7 177.80.625 15.88 8-8208 9-8245 40 65 NR NR NR 135 0.19 4.80 3 76.20.060 16 1.57 9-8210 9-8238 60 70 1.88 4.8 0.00 117 0.19 4.80 235 59690.075 14 1.91 9-8210 9-8238 60 70 1.88 4.8 0.10 118 0.19 4.80 190 48260.120 11 3.05 9-8210 9-8238 60 70 1.88 4.8 0.10 118 0.19 4.80 218 5537.20.135 10 3.43 9-8210 9-8238 60 70 1.88 4.8 0.10 119 0.19 4.80 142 3606.80.188 4.78 9-8210 9-8238 60 70 1.88 4.8 0.20 120 0.19 4.80 117 2971.80.250 6.35 9-8210 9-8238 60 70 1.88 4.8 0.30 123 0.19 4.80 66 1676.40.375 9.53 9-8210 9-8238 60 70 1.88 4.8 0.50 119 0.19 4.80 34 863.60.500 12.70 9-8210 9-8238 60 70 1.88 4.8 0.75 121 0.19 4.80 23.4 594.360.625 15.88 9-8210 9-8238 60 70 NR NR NR 135 0.19 4.80 14 355.60.750 19.05 9-8210 9-8238 60 70 NR NR NR 130 0.19 4.80 13.6 345.441.000 25.40 9-8210 9-8238 60 70 NR NR NR 135 0.19 4.80 12.8 325.12

Pierce Height RecommendedTravel speed

Stand-offHeightMaterial thickness

Gas: Compressed Air

Material: Mild SteelTorch: SL100 with Shielded TipPower Supply: CutMaster 81 Automated

Table: Dry


4

4.13 Cutting Speed Charts: Stainless Steel, SL100 Torch with Shielded Tip

NOTES




TorchTip


Press.*Pierce Time

Arc voltage

In GA mm Cat. # Cat. # Amps PSI In mm SEC Volts in mm IPM mm/min0.038 20 8-8208 9-8245 40 65 0.188 4.8 0.00 109 0.19 4.8 179 4546.60.050 18 1.27 8-8208 9-8245 40 65 0.188 4.8 0.00 109 0.19 4.8 150 38100.063 16 1.60 8-8208 9-8245 40 65 0.188 4.8 0.10 110 0.19 4.8 122 3098.80.078 14 1.98 8-8208 9-8245 40 65 0.188 4.8 0.30 111 0.19 4.8 66 1676.40.135 3.43 8-8208 9-8245 40 65 0.188 4.8 0.40 111 0.19 4.8 66 1676.40.141 10 3.58 8-8208 9-8245 40 65 0.188 4.8 0.50 112 0.19 4.8 65 16510.187 4.75 8-8208 9-8245 40 65 0.188 4.8 0.60 112 0.19 4.8 38 965.20.250 6.35 8-8208 9-8245 40 65 0.188 4.8 1.00 116 0.19 4.8 23 584.20.375 9.53 8-8208 9-8245 40 65 NR NR NR 116 0.19 4.8 16 406.40.500 12.70 8-8208 9-8245 40 65 NR NR NR 119 0.19 4.8 9 228.60.625 15.88 8-8208 9-8245 40 65 NR NR NR 121 0.19 4.8 5 1270.063 16 1.57 9-8210 9-8238 60 70 0.188 4.8 0.00 113 0.19 4.8 142 3606.80.078 14 1.98 9-8210 9-8238 60 70 0.188 4.8 0.10 115 0.19 4.8 134 3403.60.125 11 3.18 9-8210 9-8238 60 70 0.188 4.8 0.10 116 0.19 4.8 112 2844.80.135 3.43 9-8210 9-8238 60 70 0.188 4.8 0.10 118 0.19 4.8 82 2082.80.141 10 3.58 9-8210 9-8238 60 70 0.188 4.8 0.15 118 0.19 4.8 82 2082.80.187 4.75 9-8210 9-8238 60 70 0.188 4.8 0.20 119 0.19 4.8 75 19050.250 6.35 9-8210 9-8238 60 70 0.188 4.8 0.30 120 0.19 4.8 55 13970.375 9.53 9-8210 9-8238 60 70 0.188 4.8 0.50 122 0.19 4.8 28 711.20.500 12.70 9-8210 9-8238 60 70 0.188 4.8 0.75 128 0.19 4.8 17 431.80.625 15.88 9-8210 9-8238 60 70 NR NR NR 135 0.19 4.8 13 330.20.750 19.05 9-8210 9-8238 60 70 NR NR NR 139 0.19 4.8 10 2541.000 25.40 9-8210 9-8238 60 70 NR NR NR 142 0.19 4.8 4 101.6

Material: Stainless SteelTorch: SL100 with Shielded TipPower Supply: CutMaster 81 Automated





4

4.14 Cutting Speed Charts: Aluminum, SL100 Torch with Shielded Tip

NOTES




TorchTip


Press.*Pierce Time

Arc voltage

In GA mm Cat. # Cat. # Amps PSI In mm SEC Volts in mm IPM mm/min0.04 20 1.02 8-8208 9-8245 40 65 0.188 4.8 0.00 100 0.19 4.8 220 5588

0.051 1.30 8-8208 9-8245 40 65 0.188 4.8 0.00 102 0.19 4.8 220 55880.064 16 1.63 8-8208 9-8245 40 65 0.188 4.8 0.10 104 0.19 4.8 220 55880.079 14 2.01 8-8208 9-8245 40 65 0.188 4.8 0.30 108 0.19 4.8 149 3784.60.125 3.18 8-8208 9-8245 40 65 0.188 4.8 0.35 112 0.19 4.8 73 1854.20.135 3.43 8-8208 9-8245 40 65 0.188 4.8 0.40 115 0.19 4.8 69 1752.60.187 4.75 8-8208 9-8245 40 65 0.188 4.8 0.60 118 0.19 4.8 50 12700.250 6.35 8-8208 9-8245 40 65 0.188 4.8 1.00 122 0.19 4.8 25 6350.375 9.53 8-8208 9-8245 40 65 NR NR NR 129 0.19 4.8 11 279.40.500 12.70 8-8208 9-8245 40 65 NR NR NR 134 0.19 4.8 7 177.80.625 15.88 8-8208 9-8245 40 65 NR NR NR 138 0.19 4.8 4 101.60.034 22 1.57 9-8210 9-8238 60 70 0.188 4.8 0.00 101 0.19 4.8 352 8940.80.064 16 1.63 9-8210 9-8238 60 70 0.188 4.8 0.10 105 0.19 4.8 352 8940.80.125 3.18 9-8210 9-8238 60 70 0.188 4.8 0.10 109 0.19 4.8 352 8940.80.135 3.43 9-8210 9-8238 60 70 0.188 4.8 0.10 112 0.19 4.8 272 6908.80.141 3.58 9-8210 9-8238 60 70 0.188 4.8 0.15 118 0.19 4.8 220 55880.187 4.75 9-8210 9-8238 60 70 0.188 4.8 0.20 122 0.19 4.8 136 3454.40.250 6.35 9-8210 9-8238 60 70 0.188 4.8 0.30 126 0.19 4.8 76 1930.40.375 9.53 9-8210 9-8238 60 70 0.188 4.8 0.50 129 0.19 4.8 46 1168.40.500 12.70 9-8210 9-8238 60 70 0.188 4.8 0.75 136 0.19 4.8 28 711.20.625 15.88 9-8210 9-8238 60 70 NR NR NR 139 0.19 4.8 19 482.60.750 19.05 9-8210 9-8238 60 70 NR NR NR 142 0.19 4.8 14 355.61.000 25.40 9-8210 9-8238 60 70 NR NR NR 150 0.19 4.8 4 101.6

Pierce Height RecommendedTravel Speed

Stand-offHeightMaterial thickness

Material: AluminumTorch: SL100 with Shielded TipPower Supply: CutMaster 81 Automated



4

Art # A-04381 Shield Cap, Machine

Electrode Start Cartridge Tip Shield Cup Body 9-8215 9-8213 9-8237

Shield Cap, Deflector9-8243

4.15 Operator's Custom Cutting Speed Charts

TorchTip


Press.*Pierce Time

Arc voltage

In GA mm Cat. # Cat. # Amps PSI In mm SEC Volts in mm IPM mm/min



Material: Torch: SL100 with Shielded TipPower Supply: CutMaster 81 Automated



4




TorchTip


Press.*Pierce Time

Arc voltage






Manual 0-4641 5-1 SERVICE

5

SECTION 5:SERVICE

5.01 General Maintenance

A. Filter Element Replacement

The Regulator/Filter Assembly is on the rear panel. For better system performance, the Regulator/Filter Assembly filter elementshould be checked per the Maintenance Schedule (Appendix 3), and either cleaned or replaced.

1. Remove power from the power supply; turn off the gas supply and bleed down the system. Turn the regulator adjustmentknob to the 'zero' setting.

2. Unscrew the bowl on the bottom of the Regulator/Filter Assembly. The filter element will be visible and still attached tothe main body of the Regulator/Filter.

3. Grasp the filter element and unscrew it from the Regulator/Filter body. The filter element will come off with a spool andsome additional pieces.

4. Note the correct assembly of the filter/spool then remove the filter from the spool and either clean it or replace it.

5. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the Regulatorbody by compressing the spring on the spool. Tighten firmly by hand.

Art # A-02995


Spool

Bowl

Spring

FilterElementNo. 9-4414

Baffle Ring

Regulator/Filter Element Replacement

6. Reinstall the bowl.

7. Turn on the air supply.

SERVICE 5-2 Manual 0-4641

5

B. Single-Stage Filter Element Replacement

These instructions apply to power supplies where the Single-Stage Filter has been installed.

The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can beremoved from its housing, dried, and reused. Allow 24 hours for Element to dry.

1. Remove power from power supply.

2. Shut off air supply and bleed down system before disassembling Filter to change Filter Element.

3. Disconnect gas supply hose.

4. Turn the Cover counter-clockwise and remove it from the Filter Housing. The Filter Element is located inside theHousing.

Art # A-02476

FilterElement

(Cat. No. 9-7741)

Housing

Cover

BarbedFitting

Spring

Assembled FilterO-ring

(Cat. No. 9-7743)

Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry.

6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE

If unit leaks between housing and cover, inspect the "O" Ring for cuts or other damage.


5

C. Optional Two-Stage Filter Element Replacement

The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue tooperate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.

1. Shut off primary input power.

2. Shut off air supply and bleed down system.

WARNING

Always turn off the air supply and bleed down the system before disassembling the Filter Assembly as injury couldresult.

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

First & Second StageCartridges (as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.

7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may damage thegasket.

8. Slowly apply air pressure to the assembly, checking for leaks.

NOTE

A small amount of air leakage from the bottom fitting is normal.


5

D. Cleaning Torch

Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated withresidue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases,the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch andblowing it through with compressed air.

CAUTION

Dry the torch thoroughly before reinstalling.

E. O-Ring Lubrication

An O-ring on the Torch ATC Male Connector requires lubrication on a regular basis, depending on how frequently the torchis disconnected and re-connected. This will allow the O-ring to remain pliable and provide a proper seal. The O-ring will dryout, becoming hard and cracked, if the O-ring lubricant is not used on a regular basis. This can lead to performance problems.

It is recommended to apply a very light film of O-ring lubricant (Catalog # 8-4025) to the O-ring on a weekly basis.

NOTE

DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or maycontain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside thetorch. Either of these conditions can lead to inconsistent performance or poor parts life.

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring


5

5.02 Common Faults

1. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

e. Cutting current too low

f. Non - Genuine Thermal Dynamics parts used

g. Incorrect gas pressure

2. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Cutting current too high

d. Work cable disconnected

e. Worn torch parts


3. Excessive Dross Formation

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Worn torch parts

d. Improper cutting current

e. Non - Genuine Thermal Dynamics parts used

f. Incorrect gas pressure

4. Short Torch Parts Life

a. Oil or moisture in air source

b. Exceeding system capability (material too thick)

c. Excessive pilot arc time

d. Gas pressure too low

e. Improperly assembled torch


5. Difficult Piloting

a. Worn torch parts

b. Non - Genuine Thermal Dynamics parts used

c. Incorrect gas pressure


5

5.03 Basic Troubleshooting

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose orrepair unless you have had training in power electronics measurement and troubleshooting techniques.

A. Basic Troubleshooting: Overview

This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this system.

Follow all instructions as listed and complete each section in the order presented.

B. How to Use This Guide

The following information will help the Operator determine the most likely causes for various symptoms. Follow all instructionsas listed and complete each section in the order presented.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions

1. Cause

a. Check / Remedy

Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to verify that unitoperates properly after any repairs.

C. Common Symptoms

A. AC indicator OFF

1. Switch at main power panel in OFF (open) position.

a. Close main power switch.

2. Power Supply ON / OFF switch in OFF (down) position.

a. Turn switch to ON (up).

3. Torch is not connected properly to Power Supply

a. Turn power supply ON / OFF switch to OFF (down). Check torch connection to Power Supply. Tighten or adjust asrequired. Do not use tools. Turn power supply ON / OFF switch to ON (up).

4. Shield cup not fully tightened on torch head

a. Check shield cup for proper installation. Do not overtighten. Do not use tools to tighten.

CAUTION

When the shield cup is properly installed, there is a slight gap between the shield cup and the torch head. Gas ventsthrough this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing theshield cup against the torch head can damage components.

5. Main power line fuse(s) or circuit breaker(s) blown

a. Check main power panel fuse(s). Replace as required.


5

6. Unit internal fuse blown or loose

a. If blown, double-check input voltage and replace fuse per Section 5.09-C.

7. Actual input voltage does not correspond to voltage of unit

a. Verify that the input line voltage is correct. Refer to Section 2, Input Wiring Requirements.

B. Gas flows continuously when power is turned on, AC indicator flashes

1. Torch switch is activated (closed) before user turns power on.

a. Release torch switch.

2. Faulty torch switch in CNC Control.

a. Check torch switch for continuity. Replace if necessary.

C. Gas flows continuously; Torch will not pilot when torch switch is activated; AC indicator ON

1. System is in SET mode

a. Change RUN / Rapid Auto Restart / SET switch to RUN (up).

D. No gas flow; RUN / Rapid Auto Restart / SET switch in SET position; Fans operate; AC indicator ON; GAS

indicator OFF

1. Gas not connected

a. Check gas connections.

2. Gas pressure too low for power supply operation

a. Adjust pressure to 70-75 psi / 4.8 - 5.2 bar.

E. Torch will not pilot; gas flows; AC indicator ON, GAS , TEMP , and DC indicators OFF

1. Gas pressure is below power supply minimum requirement.


NOTE

Minimum pressure for power supply operation is lower than minimum for torch operation.

F. Torch will not pilot; gas flows; AC and Gas indicators ON; DC and TEMP indicators OFF

1. Gas pressure is below torch minimum requirement (Minimum pressure for power supply operation is lower thanminimum required for torch operation.)


2. Positive and negative wire connections to automation interface PC Board terminals J2-1 and J2-3 are reversed.

a. Check wire connections, correct if necessary.

NOTE

This condition applies to CNC Controllers (other than the SC-11) with semiconductor switches.


5

G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator ON

1. Start cartridge missing from torch

a. Shut off power supply. Remove shield cup, install start cartridge. Reinstall torch tip and shield cup. Turn powersupply ON / OFF switch to ON (up).

2. Shield cup is loose on torch

a. Check shield cup; tighten if necessary.

NOTE

When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield cupand torch head. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.

3. Upper O-ring on torch head is in wrong position.

a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary.

Upper Groovewith Vent HolesMust Remain Open

Threads

Upper O-Ringin Correct Groove

Lower O-Ring Art # A-03725

H. Torch will not pilot; AC , GAS , and TEMP indicators ON, DC indicator OFF

1. Air flow blocked

a. Check for blocked air flow around the unit and correct condition.

2. Unit is overheated

a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit. Referto duty cycle data in Section 2.

3. Input line voltage is low

a. Check and connect to proper input power line.


5

I. Torch cannot be activated; AC indicator flashing; Gas indicator ON; Temp indicator OFF; DC

indicator OFF

1. System is in protective interlock mode. (Torch switch in CNC Controller in ON position while turning on power supplyON / OFF switch.)


2. System is in protective interlock mode. (Torch parts are missing, defective, or loose.)

a. Release torch switch, and set power supply ON / OFF switch to OFF (down). Open main disconnect switch.Check torch parts. Replace parts as needed. Reinstall shield cup; hand - tighten it securely against the torchhead. Do not overtighten. Do not use tools. Close main disconnect switch. Set ON / OFF switch to ON (up)position.

J . Gas cycles on and off without torch switch being activated; AC indicator Flashing; Gas indicator ON; DC

indicator OFF

1. Torch tip or electrode missing

a. Shut off power supply. Remove shield cup, install missing part(s). Turn power supply ON / OFF switch to ON (up).

2. Start cartridge stuck or worn.

a. Remove the start cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end fittingfor free motion. Replace if necessary.

Art # A-07168



1/8” (3 mm)

K. No cutting output; Torch pilots; Gas flows; Fans operate; AC , Gas , and DC indicator ON;

TEMP indicator OFF

1. Work cable not connected to work piece, or connection is poor

a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece or the cutting table.

2. Faulty Torch

a. Return for repair or have qualified technician repair.


5

L. Torch cuts but not adequately

1. Incorrect setting of output current (A) control

a. Check and adjust to proper setting.

2. Torch consumables worn

a. Check torch consumables; replace as needed.

3. Work cable connection is poor

a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece or cutting table.

4. Torch is being moved too fast across workpiece

a. Reduce cutting speed.

5. Excessive oil or moisture in torch

a. Put RUN / RAPID AUTO RESTART / SET switch in SET (down) position. Hold torch 1/8 inch (3 mm) fromclean surface while purging and observe oil or moisture buildup (do not activate torch). If there are contami-nants in the gas, additional filtering may be needed.

6. Fluctuations in input power

a. Have electrician check input line voltage.

M. Arc shuts off during operation; arc will not restart when torch switch is activated.

1. Power Supply is overheated (TEMP indicator ON)

a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit. Referto Section 2 for duty cycle specifications.

2. Fan blades blocked (TEMP indicator ON)

a. Check and clear blades.

3. Air flow obstructed (TEMP indicator ON)

a. Check for obstructed air flow around the unit and correct condition.

4. Gas pressure too low (GAS indicator OFF when torch switch is activated)

a. Check source for at least 60 psi / 4.1 bar; adjust as needed. (Minimum pressure for power supply operation is lowerthan minimum required for torch operation.)

5. Torch consumables worn

a. Check torch consumables; replace as needed.

N. AC indicator remains ON when shield cup is removed

1. Faulty PIP switch in torch

a. Check PIP switch for continuity; replace if necessary


5

5.04 Advanced Troubleshooting Guide - General Information

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose orrepair unless you have had training in power electronics measurement and troubleshooting techniques.

A. General Information

This Section covers advanced troubleshooting, which requires power supply disassembly and live measurements. Advancedtroubleshooting and repair of this unit is a process which should be undertaken only by those familiar with high voltage highpower electronic equipment.

If major complex subassemblies are faulty, the faulty subassembly must be returned for repair. Refer to Repairs & ReplacementProcedures, for parts replacement instructions. Replacement instructions for some parts are included in this manual. Replace-ment instructions for parts not covered in this manual are included with the replacement part.

Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other subassemblies of this unit. Evidenceof unauthorized repairs will void the factory warranty.

NOTE

Follow all instructions as listed and complete each in the order presented.

B. How to Use the Troubleshooting Guide

The following information is a guide to help the Service Technician determine the most likely causes for various symptoms. Thisguide is set up in the following manner:

1. Perform operational check(s) on the equipment to isolate problem to possible circuit(s) per Subsection 5.06, Circuit FaultIsolation.

2. Determine symptom and isolate to defective assembly using the following format:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

3. Locate your symptom in the appropriate Subsection.

4. Check the causes (easiest listed first) for the symptom.

5. Check the remedies listed for each cause.

6. Repair as needed being sure to verify that unit is fully operational after any repairs.

NOTES

Many signals are transferred between Printed Circuit Board Assemblies on Cables. If these cables become faultythey can then cause various problems. Do not forget about these cables when troubleshooting.

While troubleshooting visually inspect the internal components for signs of overheating, fractures and damage.


5

C. Main Input and Internal Power Tests

1. Connect main AC power to the unit.

2. Set the Power Supply ON/OFF switch to ON (up) and note the following:

• AC indicator steady ON

• Gas solenoid energizes (clicks)

• Main PCB Relay energizes, pulling in main input contactor (W1)

• TEMP Indicator OFF

• GAS Indicator ON if input pressure is sufficient for power supply operation. Minimum pressure for power supply

operation is lower than minimum for torch operation.

• Gas flows

• Fans operate

• DC indicator is OFF3. Set the Power Supply RUN / RAPID AUTO RESTART / SET switch to the RUN (up) position and note the following:

• Gas flow stopsThis completes the Main Input and Internal Power Tests. If the above are all correct then proceed to paragraph ‘D’. If not, notethe symptom and proceed to Subsection 5.05, Main Input and Internal Power Problems.

D. Pilot Arc Test

1. Activate the torch to establish a pilot arc and note the following:

• Gas flows

• Preflow delay (two seconds) then DC indicator turns ON

• Pilot arc is establishedThis completes the Pilot Arc Test. If the above are all correct then proceed to paragraph ‘E’. If the unit does not function properly,then note the symptom and proceed to Subsection 5.06, Pilot Arc Problems.

E. Main Arc Test

Make sure the work cable is firmly connected to the workpiece. Activate the torch to establish a pilot arc.

Bring the torch to within 1/8"-3/8" (3-10 mm) of the workpiece to establish the main cutting arc, and note the following:

• Main cutting arc startsThis completes the Main Arc Test. If the above are all correct then the equipment should be operating properly. If problems stillpersist then contact Technical Services.

If the torch does not function as noted then note the symptom and proceed to Subsection 5.07, Main Arc Problems.


5

5.05 Main Input and Internal Power Problems

A. Opening Power Supply Enclosure

The cover of the Power Supply must be removed for access to input power connections and test points.

WARNING

Disconnect primary power at the source before assembling or disassembling the Power Supply, torch parts, or torchand leads assemblies.

1. Remove the upper screws securing the cover to the main assembly.2. Loosen, but do not remove, the lower screws.

NOTE

There is a ground wire attached from the cover to the main body of the unit.

3. Carefully lift the cover off the unit, and remove the nut securing the ground wire to the side panel.

4. Re-install the cover by reversing the above steps.

Art # A-04510

Lowerscrews

Upper screws

Ground wire

Lowerscrews

Cover Removal


5

Locate your symptom below:

A. Main power line fuses blow as soon as main disconnect is closed

1. Input power cable installed incorrectly or defective power cord.

a. Refer to Subsection 5.07 and check that the input power cable is not defective or installed incorrectly.

2. Main input contactor (W1) stuck.

a. Check contactor. Replace if stuck.

B. Main power line fuses blow immediately after the ON/OFF Switch is turned on.

1. Faulty Input Diode

a. Test Input Diode per Subsection 5.08-C; repair as necessary.

C. Fans do not operate; AC indicator OFF

1. Front Panel ON/OFF switch in OFF position

a. Place switch to ON (up) position.

2. Main power disconnect open

a. Close main power disconnect.

3. Torch is not properly connected to Power Supply.

a. Check torch connections to Power Supply. Tighten or adjust as needed.

4. Shield cup not fully tightened on torch head.

a. Check shield cup for proper installation. Do not overtighten.

5. Main power line fuses blown

a. Replace main power line fuses.

Art # A-03658

INPUTDIODE

TP1TP4 J24-3 J32J29

J18-5J23-1

J33

J27

J43

J34

J11

J15

FUSEJ23-3

J18-6

J15-1

J15-6

J15-5

J15-2

J24-1

Main Printed Circuit Board Layout (logic board not shown)


5

6. Improper input power cable connections inside Power Supply

a. Refer to System Schematic and correct if needed.

7. Defective input power cable

a. Replace input power cable. Refer to subsection 5.09-L.

8. Fuse blown inside Power Supply

a. Replace internal Fuse per Subsection 5.09-C.

9. Line voltage above 10% tolerance (over voltage protection)

a. Reduce line supply.

10. Faulty Auxiliary Transformer (refer to Appendix pages, 28 VAC Circuit Diagram)

Measure for 28 VAC on Main PC Board from J23-1 to J23-3.

a. If voltage is not present, replace the Main PC Board.

11. Faulty ON/OFF switch

Measure for 28 VAC on the Main PC Board between J18-5 to J18-6.

a. If voltage is not present replace the ON/OFF Switch.

12. Faulty Main PC Board

Measure for 12 vdc on Main PC Board from TP4 to TP1.

a. If voltage is not present, replace the Main PC Board.

D. AC and TEMP indicators ON, fans do not run

1. Air flow through unit is restricted

a. Provide adequate air flow

2. Exceeded Duty Cycle of Power Supply

a. Deactivate torch and wait for fan to cool unit. Refer to Specifications Section for proper duty Cycle for this unit.

3. Faulty Fan(s)

Measure for 230 VAC (±) on the Main PC Board from J15-1 to J15-2, and from J15-5 to J15-6.

• If voltage at J15-1 to J15-2 is correct, replace lower Fan (M1).

• If voltage at J15-5 to J15-6 is correct, replace upper Fan (M2).

4. Faulty Temperature Sensor / Switch

a. Check IGBT Heatsink Temp Sensor (TS1). Disconnect wire connector P29 from terminal J29 on Main PCBoard. Check connector pins 1 and 2 for 10K ohm (±25%) (at ambient temperature). If resistance is not 10Kohm (±25%), replace TS1.

b. Check Inductor Temp Switch (TS2). Disconnect wire connector P32 from terminal J32 on Main PC Board.Check connector pins 1 and 2 for at least 12K ohms. If resistance is less than 12K ohms, replace outputinductor (L1). If temp switch is open, replace Main PC Board.


5

E. No gas flow; AC indicator ON; TEMP , GAS and DC indicators OFF

1. RUN / RAPID AUTO RESTART / SET switch in RUN position

a. Change switch to SET position.

2. Gas supply not connected to unit

a. Connect to gas supply.

3. Gas supply not turned on

a. Turn gas supply on.

4. Faulty RUN / RAPID AUTO RESTART / SET switch

a. Check continuity.

5. Faulty Gas Solenoid circuit

a. Test Gas Solenoid circuit per Subsection 5.08-E; repair as necessary.

6. Faulty Logic Board

a. Replace logic board.

F. Gas flows; AC indicator ON; GAS and DC indicator OFF

1. Gas pressure too low

a. Set operating pressure per pressure setting label on power supply.

NOTE

Minimum pressure for power supply operation is lower than minimum required for torch operation.

2. Faulty Pressure Switch

Measure for 12 vdc from wire #10 to wire #11 at the Gas Pressure Switch, located on the right side of the unit. Refer toSystem Schematic in the Appendix pages.

a. If 12 vdc is present and pressure is above 50 psi (3.4 bar), replace Gas Pressure Switch/Solenoid Assembly. Refer toSection 5.08-A.

b. If pressure is above 50 psi (3.4 bar) and 12 vdc is not present, replace the Logic PC Board.

3. Faulty Wiring or Faulty Logic PC Board

Check for 12 vdc at Main PC Board pin J24-3 to J24-4 from the Logic PC Board. Refer to Appendix Pages, Main PC BoardLayout.

• If less than a volt, replace Logic PC Board.

G. Gas continues to flow with RUN / RAPID AUTO RESTART / SET switch in RUN position.

1. Damaged gas solenoid.

a. Turn the front panel ON/OFF switch to OFF.

• If gas continues to flow, debris from the air line is preventing the solenoid from closing. Clean or replace the solenoid.

2. Faulty RUN / RAPID AUTO RESTART / SET switch.

a. Remove one wire from the pressure switch. Check for ± 0 vdc at Main PC Board pin J24-3 to J24-4 from theLogic PC Board. Refer to Main PC Board Layout.

• If less than a volt, replace Logic PC Board.


5

3. Faulty Logic PCB.

a. Measure for approximately 12 vdc between P1-7 and TP-1 on the Logic PCB.

• If 12 vdc is present, replace Logic PCB.

• If less than 2 vdc, replace Main PCB.

TP9

TP10

TP11

TP3

TP7TP8TP5

TP1

TP2

TP4

D13 TP6

Art # A-03654D25

D33

P1-7

P1-9

Logic Board Layout


5

H. Gas flows continuously when power is turned on; AC indicator flashes

1. Torch switch is activated (closed) before user turns power on


2. Faulty torch switch

a. Check torch switch for continuity.

I. Gas cycles on and off when power is turned on; AC indicator flashes

1. Shield cup is loose.

a. Tighten shield cup by hand. Do not overtighten.

2. Torch tip, electrode, or start cartridge missing

a. Turn off power supply. Remove shield cup, install missing parts.

3. Start cartridge is stuck

a. Turn off power supply. Remove shield cup, tip, and start cartridge. Check lower end fitting on start cartridgefor free movement. Replace cartridge if lower end fitting does not move freely.

Art # A-07168



1/8” (3 mm)


5

5.06 Pilot Arc Problems

WARNING

The following tests must be performed with the power supply connected to primary input power. There are extremelydangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair without propertraining in power electronics measurement and troubleshooting techniques.


A. Torch will not pilot; gas flows; AC indicator ON, GAS , TEMP , and DC indicators OFF

1. Gas pressure is below power supply minimum requirement. (Minimum pressure for power supply operation is lowerthan minimum required for torch operation.)

a. Adjust gas pressure per pressure setting label on power supply.

B. Torch will not pilot; gas flows; AC and Gas indicators ON; TEMP and DC indicators OFF

1. Gas pressure is below torch minimum requirement (Minimum pressure for power supply operation is lower thanminimum required for torch operation.)


2. Power Supply RUN / SET switch in SET position

a. Place RUN / SET switch to RUN position.

3. Upper O-ring on torch head is in wrong position.

a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary.

Upper Groovewith Vent HolesMust Remain Open

Threads

Upper O-Ringin Correct Groove

Lower O-Ring Art # A-03725


5

C. Torch will not pilot; AC , GAS , and TEMP indicators ON

1. Air flow blocked

a. Check for blocked air flow around the unit and correct condition.

2. Unit is overheated

a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit. Referto duty cycle data in Specifications Section.

3. Input line voltage is low

a. Check and connect to proper input power line.

4. Faulty Temperature Sensor / Switch

a. Refer to Appendix 15, Main PC Board Layout. Check IGBT Heatsink Temp Sensor (TS1). Disconnect wire connectorP29 from terminal J29 on Main PC Board. Check connector pins 1 and 2 for 10K ohm (±25%) (at ambient temperature).If resistance is not 10K ohm (±25%), replace TS1.

b. Check Inductor Temp Switch (TS2). Disconnect wire connector P32 from terminal J32 on Main PC Board. Checkconnector pins 1 and 2 for at least 12K ohms. If resistance is less than 12K ohms, replace output inductor (L1). If tempswitch is open, replace Main PC Board.

5. Faulty Logic PC Board

a. Check for (±) 12vdc on Main PC Board between J43-9 and TP1. If (±) 12vdc is present, replace Logic PC Board.


a. Check for (±) 0 vdc on Main PC Board between J43-9 and TP1. If (±) 0 vdc is present, replace Main PC Board.

7. Faulty Fan(s)

Measure for (±) 230 VAC on the Main PC Board from J15-1 to J15-5, and from J15-2 to J15-6.

• If voltage at J15-1 to J15-5 is correct, replace upper Fan (M1).

• If voltage at J15-2 to J15-6 is correct, replace lower Fan (M2).


5

D. Torch will not pilot when torch switch is activated; AC and GAS indicators ON; Temp and DC

indicators OFF

1. Gas pressure too high or too low


2. Torch tip, start cartridge, or electrode missing.

a. Turn off power supply. Remove shield cup, install missing parts.

3. Start cartridge is stuck

a. Turn off power supply. Remove shield cup, tip, and start cartridge. Check lower end fitting on start cartridgefor free movement. Replace cartridge if lower end fitting does not move freely.

Art # A-07168



1/8” (3 mm)

4. Worn or faulty torch parts

a. Inspect torch consumable parts. Replace if necessary.

E. Gas flows; AC indicator and GAS indicators ON; TEMP indicator off; ON; DC indicator

off or blinks on/off once.

1. Faulty IGBT or Output Diode Module Assembly(s)

a. Check per Subsection 5.08-C; repair as needed.

2. Faulty Main PCB

a. Test; repair as needed.


5

F. Gas flows; No arc in torch; AC , GAS , and DC indicators ON; TEMP indicator off

1. Faulty IGBT(s)

a. Measure between the following points on the IGBTs:

• IGBT A: E4 to E10

E10 to E20

• IGBT B: E23 to E27

E27 to E30

Voltage should be approximately 20 vdc before the start signal is active. If voltage measures greater than 100vdc when the start signal is active, replace the respective IGBT(s).

Art # A-03659

INPUTDIODEE3

E7

E15

E10

E20

E4 J30E33

E26

E27

E30

J31 E23

J25

IGBT A IGBT B

J11

Main PC Board Layout (IGBT Test Points)


5

G. No arc or intermittent arc in torch; Gas flows; AC , GAS , and DC indicators ON; TEMP indica-

tor off

1. Gas pressure set incorrectly (too high)

a. Reset gas pressure per pressure setting label on power supply.

2. Oil/moisture in air lines

a. Purge system. If problem corrected, add filters in line with air source.

3. Incorrect torch parts

a. Inspect the torch parts; replace as needed.

4. Faulty leads

a. Check torch leads continuity.

5. Faulty torch

a. Check torch.

6. Faulty connection of wire #58 or 62 to Pilot Board

a. Check wiring connection. Refer to the System Schematic in the Appendix. Connections should be:

• Wire #58 to Pilot Board terminal E58

• Wire #62 to Pilot Board terminal E62

If wires 58 and 62 are not connected to the proper terminals, replace the Pilot Board.


a. Check for approximately 12 vdc at TP4 to TP1. If less than 2 vdc, replace the Main PC Board.

8. Faulty Logic Board or Faulty Pilot Board

a. Install a jumper between wires 58 and 62 on Pilot Board and retry piloting. If torch pilots with jumper installed, replacePilot Board. If torch does not pilot, replace Logic Board.


5

5.07 Main Arc Problems


A. Main cutting arc will not start

1. Work cable not connected.

a. Connect work cable.

B. No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached to power supply

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated against torch head (do not overtighten)

3. Parts - In - Place (PIP) not satisfied.

a. Check that shield cup is properly installed.

b. Check switch in machine torch head - for continuity.

4. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if necessary.

C. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if necessary.

D. Erratic or improper cutting output

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Current set too low at power supply

a. Increase current setting.

3. Torch is being moved too fast across workpiece

a. Reduce cutting speed.

4. Holding too high of a standoff.

a. Refer to recommended standoff heights provided in speed charts in Section 3. Adjust as needed.

5. Workpiece is painted or rusty.

a. Clean workpiece.


5

6. Faulty Main PC Board or Logic Board.

a. Measure for ±0 vdc at TP2 to TP1 on the Logic Board when attempting to transfer. Refer to Logic Board Layout.

• If TP2 goes to 0 vdc replace Output Board.

• If not, replace Main PC Board.

7. Faulty Main Input Contactor.

a. Check per Subsection 5.14-D.

B. When operating the amperage drops off after the main cutting arc starts.

1. Torch tip contacts workpiece

Raise the torch tip off the work. At output settings over 40 amps, circuitry in the power supply automatically reducesoutput current to 40 amps if the torch tip contacts the workpiece.

2. Faulty Pilot Board

a. With power off and wires E58 and E62 disconnected from the pilot board, measure for continuity between terminals#E58 and #E62. If continuity is found, replace Pilot Board.

5.08 Test Procedures

The test procedures in this subsection are referenced in the troubleshooting section.

A. Safety Precautions

1. Significant DC Voltage exists after removal of input power. Allow two minutes for discharge time. Voltage measured on inputcapacitors must be zero before performing service on the power supply.

2. Do Not touch electrical components with any part of the human body when power is applied.

3. Keep away from any moving parts.

4. Hot surfaces can cause severe burns. Allow equipment to cool before servicing.

5. Electrostatic discharge can damage printed circuit board assemblies. Transport printed circuit boards in proper antistaticshielded packages. Use proper grounding techniques with wrist strap before handling printed circuit boards.

6. Misaligned plugs can cause printed circuit board damage. Be sure plugs are properly aligned and completely seated.

7. Excessive pressure can damage printed circuit boards. Use only minimal pressure and gentle movement when disconnectingor connecting printed circuit board plugs.


5

B. Diode Testing Basics

WARNING

Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.

Testing of diode modules requires a digital volt/ohmmeter that has a diode test scale. Remember that even if thediode module checks good, it may still be bad. If in doubt, replace the diode module.

1. Locate the diode module to be tested.

2. Remove cables from mounting studs on diodes to isolate the module.

3. Set digital volt/ohmmeter to diode test scale.

4. Using the Figures for each test, check each diode in the module. Each diode must be checked in forward bias (plusto negative) and reverse bias (negative to plus) direction.

5. Connect the volt/ohmmeter positive lead to the anode (+) of the diode and the negative lead to the cathode (-) of thediode for forward bias testing (refer to following figure). A properly functioning diode will conduct in the forwardbias direction and indicate between 0.3 to 0.9 volts.

0.75

VR COM A

Art # A-00307

Anode

Cathode

Forward BiasDiode Conducting

+ _

Diode Test Symbol

OL

VR COM A

Art # A-00306

Anode

Cathode

Reverse BiasDiode Not Conducting

+ _

Testing Diode Forward Bias Testing Diode Reverse Bias

6. Reverse the meter leads across the diode for reverse bias testing (refer to following figure). A properly function-ing diode will block in the reverse bias direction and depending on the meter function will indicate an open or“OL”.

7. If a diode checks bad, replace the diode module.

8. Reconnect all cables.


5

C. Diode Module Board Tests

WARNING

Disconnect primary power at the source before taking any resistance checks.

1. Input Diode Test

a. Disconnect input AC power.

b. Check Input Diode for shorted input diode. With an ohmmeter set on the diode range make the following checks fromMain PC Board to Input Diode:

For 400-Volt, 415-Volt, 460-Volt, and 600-Volt Power Supplies: For 208/230-Volt Power Supplies:

Meter + Meter - IndicationE15 E1 Diode DropE1 E15 Open

E15 E2 Diode Drop E2 E15 OpenE15 E3 Diode DropE3 E15 OpenE7 E1 OpenE1 E7 Diode DropE7 E2 OpenE2 E7 Diode DropE7 E3 OpenE3 E7 Diode DropE7 E15 Open

E15 E7 Diode Drop*

400V, 415V, 460V, and 600V Input Diode Indications

* Indication can be twiceother indications.

Meter + Meter - IndicationE7 E1 OpenE1 E7 Diode Drop

E15 E1 Diode DropE1 E15 Open

E15 E7 Diode Drop*E7 E15 Open

208/230V Input Diode Indications

* Indication can be twiceother indications.

c. The meter should indicate a diode drop in one direction and an open in the other direction for each check. Replace theInput Diode Module Board if the readings do not match the chart.

d. If Input Diode Module Board is shorted, make the following checks with an ohmmeter at the Main Contactor (W1):

Meter (+) Meter (-) IndicationL1 T1 OpenL2 T2 OpenL3 T3 Open

If any test has resistance, then replace the Main Contactor.


5

2. Output Diode Module Board Circuit Test

a. Use an ohmmeter set on the diode function and make the following measurements on the Output Diode Module Boardsto Power Output PC Board.

IndicationMeter + Meter - Meter + Meter -

E37 E58 E36 E57 Diode Drop *E58 E37 E57 E36 OpenE37 E47 E36 E49 Diode DropE47 E37 E49 E36 OpenE58 E47 E57 E49 OpenE47 E58 E49 E57 Diode Drop

Output Diode A Output Diode B

* Indication can be twice other indications.

b. The meter should indicate a diode drop in one direction and an open in the other direction for each check.Replace the Output Diode Module Board(s) if the readings do not match the chart.

3. IGBT Module Board Circuit Test

a. Use an ohmmeter set on the diode function and make the following measurements on the IGBT Module Board(s) to theMain PC Board.

IndicationMeter + Meter - Meter + Meter -

E10 E4 E27 E23 Diode DropE4 E10 E23 E27 Open

E10 E20 E27 E30 OpenE20 E10 E30 E27 Diode DropE4 E20 E23 E30 Open

E20 E4 E30 E23 Diode Drop *

IGBT PCB A IGBT PCB B

* Indication can be twice other indications.

b. The meter should indicate a diode drop in one direction and an open in the other direction for each check.Replace IGBT Module Board(s) if readings are not the same as the chart.


5

D. Main Input Power Test

WARNING

The following tests must be performed with the power supply connected to primary input power. There are extremelydangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair without propertraining in power electronics measurement and troubleshooting techniques.

Reconnect power and observe proper start-up procedure. AC indicator on the Front Panel should be ON. If indicator is OFF thereis no voltage to the Power Supply or an overvoltage condition exists.

1. If AC indicator on Front Panel is OFF, check for proper AC input voltage between input cables on the Main Contactor.Input voltage should be as shown in the following chart. If not, check for proper voltage at the main power source.

NominalInput Voltage

ContactorPoints

VoltageRange

208/230VAC L1, L2 187-253VAC400VAC L1, L3 360-440VAC415VAC L1, L3 370-460VAC460VAC L1, L3 414-506VAC600VAC L1, L3 517-632 VAC

Contactor Voltage Readings

Art # A-03194

Main Contactor

#13

#5

L1 L2 L

3T1 T2 T3To E3

Connections to Main PCB

#4#12

To E1

To E2

Input Side

L1

L3

L2

Art # A-03212

L1 L2 L3 L4

T1 T2 T3 T4

#13

#12

#78

L1L2

InputSide

#5

#4

#3#2

#1

Main Contactor

Main Input Contactor (460-Volt Three-Phase Input Power Shown) 208/230-Volt Main Input Contactor

2. Check for 28 VAC at J23-1 to J23-3 on the Main PC Board.

a. If greater than 30 VAC, input line power is too high.

b. If there is no AC power, check the fuse. If the fuse is okay, the auxiliary transformer is faulty. Replace theMain PC Board.


5

E. Gas Solenoid Circuit Test

Make the following voltage checks and replace the faulty part as required.

1. Place the RUN / RAPID AUTO RESTART / SET Switch to the SET position.

2. Measure for 28 VAC across Solenoid wires #8 and #9. Refer to System Schematic in Appendix Section.

• If 28 VAC is present, replace Solenoid/Pressure Switch Assembly.

• If 28 VAC is not present, check for 65 psi (4.5 bar) at the pressure regulator.

3. Check for less than 2 vdc at P1-7 to TP1 on Logic Board.

• If less than 2 vdc, replace Main PC Board.

• If more than 2 vdc, replace Logic PC Board.

F. Output Power Tests

1. No DC Output

a. Activate the torch.

• If INV ON indicator D13 on Logic PC Board does not turn ON, then replace the Logic PCB.

• If the INV ON indicator D13 blinks ON then OFF immediately, perform the following test:

WARNING

The following tests must be performed with the power supply connected to primary input power. There areextremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repairwithout proper training in power electronics measurement and troubleshooting techniques.

The next step will defeat the safety interlock feature. Proceed with caution.

b. Remove the tip and electrode from the torch. Attach the work lead to the pilot return (E35 or E62) on the Output PowerBoard. Activate the torch switch. Gas should flow, then stop after 2 seconds. Front panel DC indicator shouldturn on.

c. Measure open circuit voltage between E61(+) to E43 (-) at the Output Power PC Board. Voltage should be greater than200 V. If voltage is less than 10 V, refer to the diode test measurements in Section 5.10-C.

2. Gate Drive & Sensing

a. After checking all previous steps, jumper TP1 to TP7 on the Logic PCB. Refer to Logic Board layout.

b. When the unit is turned on, the DC light should remain ON.

c. Activate the torch. After two seconds INV ON Indicator (D13) on the Logic PCB should come on and remain on.

• If INV ON indicator does not remain on, replace Logic PCB.

• If INV ON indicator remains on, then check for at least 2 vdc between TP-1 to TP-11 and between TP-1 to TP-10 on theLogic PCB. Refer to Logic Board Layout.

• If no voltage, replace Logic PC Board.

• If voltage is correct, measure for at least 2 vdc between points as in the following chart:

E11 J2A E11 J2BE19 J10A E19 J10B

IGBT A IGBT B

• If voltage is 0, replace Main PCB.


5

5.09 Power Supply Major External Parts Replacement

WARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

For replacement of parts not covered in this section, instructions are provided with the replacement part.

A. Cover Removal

1. Remove the upper screws which secure the cover to the main assembly.

NOTE

There is a ground wire connection to the inside of the unit. There is no need to disconnect the ground wire, unlessthere is a need for more room to work.

Art # A-04510

Lowerscrews

Upper screws

Ground wire

Lowerscrews

2. Loosen, but do not remove, the lower screws, then carefully pull the Cover up and away from the unit.


5

B. Tube Handle Replacement

1. Remove the power supply cover per Section 5.09-A.

2. Remove the four bolts and star washers securing the tube handles to the base of the unit.

3. Move the input power cable, torch leads and work cable inside the handle, then lift the base of the unit away from theTube Handle.

4. With a rubber mallet, separate the two handle ends as shown below.

5. Install the replacement Tube Handle by reversing the above steps.

6. Reinstall the power supply cover.

Art # A-02847

C Cover Installation

1. Reconnect the ground wire, if necessary.

2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws.

3. Tighten lower screws.

4. Reinstall and tighten the upper screws.


5

5.10 Front Panel Parts Replacement

WARNING

Disconnect input power at the source and bleed down the system before attempting these procedures.

A. Current (A) Control Knob Replacement

1. Turn the control knob fully clockwise and note the location of the pointer on the knob.

2. Loosen the screw securing the Knob to the potentiometer shaft and remove the Knob.

3. Place the replacement Knob on the potentiometer shaft with the location of the pointer the same as noted in step 1.

4. Tighten the screw to secure the knob to the potentiometer shaft.

B. ON/OFF Switch (SW1) Replacement


2. Disconnect the wires on the rear of the ON/OFF Switch. Note the location of each wire, as shown below:

Art # A-02774

Wire #21

Wire #24

Top clip

Wire #22

Wire #23

3. Squeeze together the clips on the top and bottom of the Switch. Remove the Switch through the Front Panel.

4. Install the replacement Switch by reversing the above steps.



5

C. RUN / RAPID AUTO RESTART / SET Switch (SW2) Replacement


2. Disconnect the wires on the rear of the Switch. Note the location of each wire, as shown:

Art # A-03906

Wire #25

Wire #26

Top clip

Wire #46

3. Squeeze together the clips on the top and bottom of the Switch, then remove the switch through the Front Panel.

4. Install the replacement Switch by reversing the above steps.


D. POT/LED PC Board Replacement


2. Remove Current Knob .

3. Disconnect wire harness Connector from POT/LED PC Board.

4. Remove PC Board from standoffs.

5. Install the replacement POT/LED PC Board by reversing the above steps.



5

5.11 Left Side Internal Parts Replacement

A. Fuse (F1) Replacement


2. Locate the internal fuse on the left side of the center chassis.

3. Replace the fuse. A replacement fuse is located inside the power supply. Refer to Section 6, Parts Lists, for replacementfuse catalog number.


Art # A-03002

Fuse Location

Internal Fuse Location


5

B. Main Input Contactor (W1) Replacement


2. Label all wires connected to the Input Contactor.

3. Disconnect wires to the Input Contactor from the input cable.

4. Disconnect all other wires connected to the Input Contactor.

5. Remove the two nuts and washers securing the Input Contactor to the base of the power supply.

6. Position the replacement Input Contactor with the row of connectors labeled L toward the rear of the Power Supply.Fasten in place with the hardware removed previously.

7. Complete the wiring connections as shown.

NOTE

It is important that wires are installed correctly, as shown, to prevent damage to the unit.


Art # A-03194

Main Contactor

#13

#5

L1 L2 L

3T1 T2 T3To E3


#4#12

To E1

To E2

Input Side

L1

L3

L2

Art # A-03212

L1 L2 L3 L4

T1 T2 T3 T4

#13

#12

#78

L1L2

InputSide

#5

#4

#3#2

#1

Main Contactor

400-Volt, 415-Volt, 460-Volt, and 600-Volt Input Contactor 208 / 230-Volt InputContactor

(3-phase input power connections shown)


5

C. Logic PC Board Replacement

Follow the antistatic instructions provided with the replacement part. The Logic PC Board connects to the Main PCBoard through an extender board perpendicular to both boards.


2. Remove the bolts in each corner of the Logic PC Board.

3. Detach the Logic PC Board and the extender board from the Main Power PC Board. Detach the extender board from theLogic Board.

4. Install the replacement Logic PC Board by reversing the above steps. The pins on the right edge of the Logic PC Boardmust fully engage the sockets on the edge of the extender board. The extender board must fully engage sockets on theMain Power PC Board.

D. IGBT Circuit Board or Input Diode Board Replacement

Follow the antistatic instructions provided with the replacement part. The Power Supply includes two IGBT Circuit PC Boards.

NOTE

Follow the electrostatic discharge instructions provided with the replacement component to prevent damage tothe component.

Thermal pads, heatsinks, and the large flat surface on the back of diodes and IGBTs must be kept clean. Diodes andIGBTs must not be bent or allowed to pick up any foreign material. A very clean installation between the moduleand the heatsink or chassis is essential for proper operation.


2. Turn the Power Supply onto its side.

3. Locate the IGBT Circuit PC Boards or Input Diode mounted within the Main Power PC Board. Refer to Appendix pagesfor location and position.

4. For IGBTs, remove the small jumpers between the IGBT and the Main PC Board. Transfer these jumpers to the replace-ment IGBT. Label, then remove all other wire connections to the Board(s) being replaced. Note the routing of wires.Ensure that the wires are put back in the same place when installing the replacement module.

5. Remove screw(s) securing PC Board(s) to the heatsink and remove board(s) from the Power Supply.

6. Use isopropyl alcohol and a clean rag to clean the heatsink or chassis area behind the component being replaced. Cleanthe large flat surface on the back of the replacement component. Do not scratch or abrade the surface.

7. The thermal pad(s), provided with the replacement part, is a thin metal pad. Remove any loose protective paper coveringsfrom the pad(s).

NOTE

Protective coverings must be removed from the thermal pads. Installing thermal pads with protective coverings inplace will cause equipment damage or failure.


5

8. Install replacement components as follows:

For Input Diodes:

Diode Assembly

Art # A-03950

Thermal Pad

Slot

Input Diode Replacement

a. Apply the thermal pad to the flat surface of the diode. Align the pad with the rectangular flat surface on the back ofthe device.

b. Align the diode horizontally, with its longer edges perpendicular to the power supply base.

c. Secure the device and rectangular pad to the chassis with the replacement screws and washers.

9. Torque screw(s) to 35 in-lb / 3.95 Nm.

NOTE

Failure to torque properly will cause component damage.

10. Connect wires per the chart.

Input Diode To Main PCB Input Diode To Main PCBE5 E1 E5 E1

E13 E2E18 E3

E6, E8 E7 E6, E8 E7E14, E16 E15 E14, E16 E15

400V, 415V, 460V, 600V Units208/230V UnitsCutMaster 81 Input Diode Connections

E13, E18 E2


5

For IGBTs:

a. Apply a round thermal pad to the heatsink with a small piece of light-duty tape. The tape must cover no more than 1/8" (3 mm) of the edge of the thermal pad. Use the screw hole in the heatsink as a guide to position the board.

Washer

Screw

Output Diodeor IGBT

Round Thermal Pad

Art # A-03702

Tape

Tape

b. Secure replacement board(s) with the screw removed previously. Ensure that the washer is under the head of thescrew.

9. Torque screw(s) to 17 in-lb. (1.9 Nm).

NOTE

Failure to torque properly will cause component damage.

10. Connect wires per the chart.

IGBT AConnector

To Main PCBConnector

IGBT BConnector

To Main PCBConnector

J3 J25 J3 J31J7 J30 J7 J26

E9, E11 E10 E9, E11 E27E19, E21 E20 E19, E21 E30E12, E17 E4 E12, E17 E23

IGBT A IGBT BCutMaster 81 IGBT Connections

11. Stand the unit upright; reinstall the cover.


5

E. Main PC Board Replacement

Follow the antistatic procedures provided with the replacement part.


2. Remove the Logic PC Board.

3. Remove the POT/LED PC Board.

4. Disconnect all wire and cable connections to the Main PC Board, including the connections from the three smaller PCBoards. Refer to the Main PC Board Wiring Diagrams in the Appendix pages if necessary.

5. Remove the two long Transformer screws securing the Auxiliary Transformer to the Center Chassis.

6. Remove the other screws securing the PC Board to the Center Chassis.

7. Carefully remove the original PC Board.

8. Install the replacement PC Board by reversing steps above. It may be easier to install the PC Board if the Power Supplyis turned on its right side first. Torque the screws to 17 inch-pounds (1.9 Nm).

Art # A-03909

Auxiliary Transformer

IGBT OutputDiode

AttachmentScrews

1 3

9

54

2

6 7

8

10 11

12

9. Reconnect all wiring. Refer to the Appendix pages in this manual for wiring details.


5

F. Input Power Cable Replacement


2. Locate and label the input power cable connections and disconnect the cable.

Art # A-03194

Main Contactor

#13

#5

L1 L2 L

3T1 T2 T3To E3


#4#12

To E1

To E2

Input Side

L1

L3

L2

Art # A-03212

L1 L2 L3 L4

T1 T2 T3 T4

#13

#12

#78

L1L2

InputSide

#5

#4

#3#2

#1

Main Contactor

Main Input Contactor (400-Volt, 415-Volt, 460-Volt, 600-Volt) Main Input Contactor (208/230Volt)

3. Unthread the retaining nut on the Input Cable Strain Relief on the inside of the Rear Panel and remove the Input PowerCable from the unit.

4. Install the replacement Input Power Cable by reversing the above steps. The Input Power Cable ground wire requires aring terminal.

G. EMI Filter Replacement (CE Units Only)


2. Label the input power cable connections and the cable connections to the main input contactor.

3. Disconnect all wire and cable connections to the EMI Filter.

4. Remove the hardware securing the EMI Filter. This hardware passes upward through the base of the power supply.

5. Put the replacement EMI Filter in position and secure it with the hardware removed in Step 4.

6. Connect the input power cables and the cable connections to the main input contactor.

7. Test the Power Supply for proper operation.


5

5.12 Right Side Internal Parts Replacement

A. Fan Replacement (M1, M2)


2. Label, then carefully remove the wiring connectors from the terminals on the Fans.

3. Disconnect the Work Cable from terminal E61 on the Power Output Board.

4. Remove one bolt from the Front Panel of the Power Supply, near the Control Panel. Pull the Front Panel slightly away fromthe Power Supply.

5. Remove one nut from a stud at the bottom of the Fan Assembly Panel.

6. Lift the Fan Assembly Panel and pull it out of the Power Supply.

7. Remove two bolts per Fan. Set the Fan(s) aside.

8. Install the replacement Fan Assembly as follows:

a. Fasten Fan(s) in position with the wiring connectors at the bottom of the Fan(s).

NOTE

Only two screws are needed to attach the Fan to the Fan Panel. They can be installed in any two holes providedthey are opposite each other. For grounding purposes, one of those screws must be installed with a star washer.

b. Place the Fan Assembly Panel in position in the Power Supply.

1. The inner edge of the Panel has tabs that engage slots in the center chassis. Ensure that these tabs fully engagein the chassis.

2. Press the Panel downward. Press the bottom flange fully against the bottom panel of the Power Supply.

3. Ensure that the hole in the bottom flange of the Fan Assembly Panel engages the mounting stud.

c. Replace nut on the bottom mounting stud.

d. Ensure that the Fan Panel's top flange is fully against the top forward edge of the Heatsink Shroud.

e. Press the front panel of the Power Supply against the Fan Panel, and fasten in place with the bolt removed in Step 2.

f. Secure the nut on the stud at the bottom of the Fan Panel.

9. Re-connect the wires to the Fan Assemblies.

10. Pass the Work Cable through the hole in the bottom of the Fan Panel. Ensure that the grommet is in place in the hole.

11. Connect the Work Cable to terminal E61 on the Power Output PC Board. Secure the Work Cable Strain Relief.

12. Re-install the Power Supply Cover.


5

B. Work Cable Replacement

1. Remove the cover per Section 5.09-A.

2. Disconnect the Work Cable from the E61 (WORK) terminal on the Power Output PC Board, located on the right side of theunit.

3. Squeeze the top and bottom of the Work Cable Strain Relief and remove from the Front Panel.

4. Remove Work Cable from the unit.

5. Install the replacement Work Cable.

a. Ensure that the replacement Work Cable passes through the grommet in the Fan Assembly Panel.

b. Secure the Cable to the Work terminal on the Power Output PC Board and securing the strain relief.

C. Pilot PC Board Replacement

The Pilot PC Board mounts to the Power Supply center chassis. Refer to Pilot Board Layout in the Appendix.


2. Label and disconnect wires from Pilot PC Board terminals E58 and E62. Disconnect the wire harness from receptacle J28.

3. Remove the hardware securing the Pilot PC Board to the power supply center chassis. Remove the Pilot PC Board.

4. Position the replacement Pilot PC Board against the standoffs fastened to the center chassis. Note that the Pilot PC Boardmounts with its printed text upside down. Fasten the Pilot Board to the standoffs with the hardware removed previously.Torque the hardware to 18 in-lbs (2.04 Nm).

5. Reconnect the wires to the Pilot PC Board. Wire #58 connects to terminal E58; wire #62 connects to terminal E62. Ensurethat the wire harness connector is fully seated in receptacle J28.



5

D. Pressure Switch/Solenoid Assembly Replacement

The Pressure Switch and Solenoid Valve are one Assembly. Disconnect primary input power and bleed down the system.


2. Disconnect the following wires:

a. Wires #10 and #11 from the Pressure Switch Assembly.

b. Wires #8 and #9 from the Solenoid Assembly.

3. Push the clip on the front of the Heatsink Shroud to the left to release the Solenoid Assembly. Dislodge the Assemblyfrom underneath the clip on the top of the Heatsink Shroud.

HeatsinkShroud

Dislodge SolenoidAssembly

Push Clipto the left to

release SolenoidAssembly

Art # A-03705

2

3

1

4. Release the hose from the Adapter Fitting on the input side of the Solenoid Assembly. Hold a wrench or similar toolagainst the locking ring on the Fitting, then pull on the hose to release it.

5. Release the hose from the Adapter Fitting on the output side of the Solenoid Assembly.

6. Install the replacement Pressure Switch/Solenoid Assembly by reversing steps 2-5. Once installed, the Solenoid Assem-bly should fit securely on the Heatsink Shroud. It should not be moveable.

7. Re-install the power supply cover.


5

E. Heatsink Shroud Assembly Removal

The Heatsink Shroud Assembly must be disengaged for access to either the Main Transformer or the Output Inductor. Followthese steps for access to either component.


2. Release the tab on the vertical face of the Heatsink Shroud securing the Solenoid/Pressure Switch Assembly in position.

3. Remove the gas hose from the Regulator Fitting on the back panel of the Power Supply by pressing on the locking ringon the elbow fitting, while pulling on the hose.

4. Remove the Power Supply Back Panel per subsection 5.07-D.

Remove the grommets from the two holes on the right (rear) edge of the Heatsink Shroud.

5. Remove the Fan Assembly per subsection 5.08C.

6. Label and disconnect the wires connected to the Pilot PC Board.

7. Remove the hardware securing the Pilot PC Board in place. Pull the PC Board off the center chassis.

8. Label and disconnect wires No. 45, 47, 49, and 52 from the Power Output PC Board.

9. Disconnect the wires from the Output Inductor to terminal E43 on the Power Output PC Board.

Disconnect the torch receptacle ground wire connected to the center chassis.

10. Remove nuts on two studs at the top corners of the Heatsink Shroud, and nuts on two studs on the bottom flange of theHeatsink Shroud.

12. Remove the Heatsink Shroud as follows:

a. Use the open left end of the Heatsink Shroud and the Pressure Switch/Solenoid opening as handles.

b. Pull the Heatsink Shroud away from the center chassis, and then up. It may be necessary to pry the top and bottomflanges of the Heatsink Shroud slightly to release them from their mounting studs. Movement will be limited by thewiring harness.


5

F. Main Transformer Removal and Replacement

1. Disengage the Heatsink Shroud per Paragraph E.

2. Disconnect wires #27 and 32, connected to terminals E27 and E32 on the Main Power PC Board. Pull these wires throughthe hole in the center chassis.

3. Remove the transformer.

a. Lift the Main Transformer slightly. Swing its left edge away from the center chassis. Pull its right edge away from thecenter chassis.

b. Lift it out of the Power Supply through the opening at the rear of the Power Supply.

4. Position the replacement Main Transformer behind the Heatsink Shroud Assembly. Position its wires at the right edge(as you face it) of the transformer.

5. Install the replacement transformer as follows:

a. Pass the tabs on the right edge of the base of the transformer into slots in the center chassis of the Power Supply.

b. Swing the transformer against the chassis, and pass the tabs on the left edge of the base into slots in the chassis.Press the transformer downward to lock it into position.

c. Check for proper installation; the transformer should remain securely in place.

6. Pass wires #27 and 32 through the hole in the center of the main chassis. Connect wire #27 to terminal E27 and wire #32to terminal E32 on the Main Power PC Board.

7. Reinstall the Heatsink Shroud Assembly per sub-section H.

G. Output Inductor Assembly Removal and Replacement

1. Disengage the Heatsink Shroud per paragraph E.

2. Disconnect the wires to the thermal switch on the Output Inductor.

3. Remove hex nuts at the left forward and right rear corners of the Inductor base.

4. Remove the Inductor as follows:

a. Note the position of the wires leading from the Inductor.

b. Lift out the Inductor through the opening at the rear of the Power Supply. It may be necessary to lift the Main Transformerslightly to create room for the Inductor to pass through the rear opening.

5. Install the replacement Inductor.

a. Put the replacement Inductor in place, with the wires oriented the same way as the original Inductor.

b. Secure the Inductor in place with hex nuts at opposite corners of the Inductor base.

6. Reconnect the wires to the thermal switch on the Output Inductor.

7. Replace the Heatsink Shroud per paragraph I.


5

H. Heatsink Shroud Assembly Replacement

1. Pass transformer wires #45 and 49 through the upper hole in the right (rear) edge of the Heatsink Shroud. Pass trans-former wires #47 and 52 through the lower hole.

2. Route wires as follows:

a. Pass the red wires from the output inductor through the upper hole in the right (rear) edge of the Heatsink Shroud.

b. Pass the black wires from the output inductor through the lower hole in the right (rear) edge of the Heatsink Shroud.Refer to Appendix 11, Power Output Board Layout.

c. Pass the wires from the temperature switch on the Output Inductor through the upper hole in the Shroud.

3. Re-install the Heatsink Shroud as follows:

a. Lift the Heatsink Shroud (Assembly) into position. Studs on the Power Supply base pass through holes in thebottom flange of the Shroud.

b. Swing the top edge of the Shroud Assembly into place. Studs on the Center Chassis of the Power Supply passthrough holes in the top flanges of the Shroud.

c. Ensure that the rubber feet on the Main Transformer engage holes in the Shroud.

d. Put hex nuts on the studs. Tighten the nuts on the right (rear) top and bottom studs. Leave the nuts on the left(forward) studs loose temporarily.

4. Put the Fan Assembly in place per subsection 5.12-A. Reconnect the work cable to terminal E61 on the Power OutputPC Board.

5. Tighten the nuts securing the left edge of the Heatsink Shroud Assembly. The stud and nut on the bottom left edgefasten a wire stay to the Power Supply.

6. Replace the grommets around the wire harnesses passing through the right (rearward) edge of the Heatsink Shroud.

7. Reinstall the Pilot Board. Reconnect the wires to the Pilot Board.

Reconnect the torch receptacle ground wire to the center chassis.

9. Replace the Pressure Switch/Solenoid Assembly. This assembly fits into a slot in the top horizontal surface of theHeatsink Shroud. A notched pin holds the assembly in place.

10. Connect the gas hose between the Regulator/Filter Assembly and the Gas Pressure Switch/Solenoid Assembly.

11. Connect wiring to the Output Power PC Board. Refer to the Appendix pages for wiring layout.

12. Replace the Power Supply rear panel per subsection 5.07-D.

This concludes the replacement procedures.


5

This Page Left Blank

Manual 0-4641 6-1 PARTS LISTS

6

SECTION 6:PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

Section 6.03 Complete Power Supply Replacements

Section 6.04 Power Supply Basic Replacement Parts

Section 6.05 Power Supply Options and Accessories

Section 6.06 Power Supply Major External Replacement Parts

Section 6.07: Power Supply Front Panel Replacement Parts

Section 6.08: Power Supply Left Side Replacement Parts

Section 6.09: Power Supply Rear Panel Replacement Parts

Section 6.10: Power Supply Right Side Replacement Parts

Section 6.11: Torch Replacement Parts (SL100 Torch - no Solenoid on Mounting Tube)

Section 6.12: Torch Replacement Parts (SL100SV Torch - with Solenoid on Mounting Tube)

Section 6.13: Torch Consumable Parts

Section 6.14: Torch Spare Parts Kits

Section 6.15: Complete Torch Replacements

Section 6.16: Torch Options and Accessories

NOTE

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your distributor. Materials returned without proper authorizationwill not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the partslist for each type item. Also include the model and serial number of the power supply. Address all inquiries to yourauthorized distributor.

6.03 Complete Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressureregulator / filter, and operating manual.

Qty Description Catalog #

CutMaster 81 Automation Power Supply1 208 / 230VAC, Single-Phase, 50 / 60Hz, with input power cable and plug 3-1121-11 400VAC, Three - Phase, 50 /60Hz, with input power cable 3-1121-31 400VAC, Three - Phase, 50 Hz , with input power cable, CE 3-1121-41 415VAC, Three - Phase, 50 Hz , with input power cable, CE 3-1121-61 460VAC, Three - Phase, 60 Hz, with input power cable 3-1121-21 600VAC, Three - Phase, 60 Hz, with input power cable 3-1121-5

PARTS LISTS 6-2 Manual 0-4641

6

6.04 Power Supply Basic Replacement Parts


Fuse1 for 208 / 230VAC Power Supply 9-85881 for 400 / 415 VAC Power Supply 9-86021 for 460 VAC Power Supply 9-85831 for 600 VAC Power Supply 9-86381 Regulator / Filter Assembly Replacement Element 9-4414

6.05 Power Supply Options and Accessories


1 Two-Stage Filter Kit (includes Hose & Mounting Screws) 7-75001 Bracket, Filter Mounting (not shown) 9-75351 Two-Stage Air Filter Assembly 9-75271 First Stage Cartridge 9-10211 Second Stage Cartridge 9-10221 Single-Stage Filter Kit (includes Filter & Hose) 7-75071 Replacement Filter Body 9-77401 Replacement Filter Hose (not shown) 9-77422 Replacement Filter Element 9-7741

1 Extended Work Cable ( 50 ft /15.2 m ) with Clamp 9-85291 Multi-Purpose Cart 7-88881 25' / 7.6 m CNC Interface Cable 9-83121 50' / 15.2 m CNC Interface Cable 9-83131 75' / 22.8 m CNC Interface Cable 9-83151 100' / 30.4 m CNC Interface Cable 9-83161 125' / 38.0 m CNC Interface Cable 9-83171 Vinyl Cover 9-7072

Art # A-02476

FilterElement

(Cat. No. 9-7741)

Housing

Cover

BarbedFitting

Spring

Assembled FilterO-ring

(Cat. No. 9-7743) First & Second

StageCartridges (as marked)

Art # A-02942

Single-Stage Filter Kit Optional Two-Stage Filter Kit


6

NOTE: Illustration may vary slightly from unit.

6.06 Power Supply Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-79972 Rear Panel (provide data tag information when ordering)

1 For 208/230-Volt Power Supplies 9-83231 For 400-Volt, 415-Volt, 460-Volt, and 600-Volt Power Supplies 9-8322

2 1 Tube, roll handle 9-7998

Art # A-03709

3

3

1

2


6

6.07 Power Supply Front Panel Replacement Parts

Item# Qty Description Ref. # Catalog #

1 1 Knob, Fluted, Skirted, 0.250 I.D. 9-85272 1 On/Off Rocker Switch SW1 8-32583 1 Run / Rapid Auto Restart / Set Switch SW2 9-10424 1 Assembly, Pot / LED PC Board 9-80045 1 Work Cable, #6 AWG, with Clamp, 20 Ft. (6.1 m) See Note6 1 Work Cable, #6 AWG, with Clamp, 20 Ft. (6.1 m) 9-8528


Art # A-06756

1

2

3

4

5

6

Note:

Item # 6 replaces Item #5.


6

6.08 Rear Panel Replacement Parts

Item # Qty Description Ref. Catalog #

1 1 Assembly, Filter/Regulator 9-75142 1 Regulator/Filter Replacement Element 9-44143 1 Regulator Mounting Bracket 9-75894 Input Power Cable

1 for 208/230-Volt Units 9-85961 for 400-Volt Three-Phase units 9-85621 for 400-Volt / 415-Volt CE units 9-85531 for 460-Volt Three-Phase units and 600-Volt Three-Phase units 9-8593

5 1 Mounting Nut 9-58046 1 Pressure Gauge 9-1045


Art # A-03005

2

13

4

5

6


6

6.09 Power Supply Left Side Internal Replacement Parts

Item # Qty Description Ref # Catalog #

1 1 Fuse F1for 208/230-Volt Power Supplies 9-8588for 400 / 415-Volt Power Supplies 9-8602for 460-Volt Power Supplies 9-8583for 600-Volt Power Supplies 9-8638

Main Input Contactor W12A for 208/230-Volt Power Supplies 9-85872 for 400-Volt, 415-Volt, 460-Volt and 600-Volt Power Supplies 9-85543 1 Connector PC Board 9-85764 1 PC Board Assembly, Logic 9-79925 1 PC Board Assembly Kit, IGBT Circuit

for 208/230-Volt, 400-Volt, 415-Volt, and 460-Volt Power Supplies 9-8578IGBT PC BoardRound Thermal Pad

for 600-Volt Power Supplies 9-8646IGBT PC BoardRound Thermal Pad

6 1 PC Board Assembly Kit, Input Diode 9-7088Input Diode PC BoardRectangular Thermal Pad

7 1 PC Board Assembly, Main Powerfor 208/230-Volt Power Supplies 9-7986for 400-Volt Power Supplies 9-7990for 415-Volt Power Supplies 9-8669for 460-Volt Power Supplies 9-7989for 600-Volt Power Supplies 9-7991

8 1 EMI Filter (for CE Power Supplies only) 9-7667


6


3

5

4

1 7

5

Art # A-03717

6

22AOR

8


6

6.10 Right Side Internal Replacement Parts

Item # Qty Description Ref #. Catalog #

1 1 Assembly, Pressure Switch/Solenoid Sol1, Ps1 9-83292 1 Assembly, Pilot Board 9-79853 1 Fan, 220V, 115 CFM M1, M2 9-76874 1 Assembly, Main Transformer T5

for 208/230-Volt units 9-8589for 400-Volt / 415-Volt units 9-8603for 460-Volt units 9-8584for 600-Volt units 9-8635

5 1 Assembly, Output Inductor L1 9-85916 1 Assembly, Output Power PC Board 9-79887 1 Assembly, Output Diode PC Board 9-8580

1 Round Thermal Pad8 1 Automation Interface PC Board 9-48949 1 Automation Interface Wire Harness 9-4895

10 1 Transformer (only in power supplies connected to SL100SV Torch 9-9449(with solenoid on mounting tube)


6


2

3

5

1

7

4

6

Art # A-07120

Work Cable

Output DiodeHeatsink

IGBT Heatsink

HeatsinkShroud

FanShroud

3

7

8

8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1

9

10


6

6.11 Torch Replacement Parts

SL100 Torch

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220

2 1 Large O - Ring 8-3487

3 1 Small O - Ring 8-3486

4 1 PIP Switch Kit 9-7036

5 1 PIP Plunger and Return Spring Kit 9-7045

6 Automated Leads Assemblies with ATC connectors

1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850




7 1 11" / 279 mm Rack 9-7041

8 1 11" / 279 mm Mounting Tube 9-7043

9 1 End Cap Assembly 9-7044

10 2 Body, Mounting, Pinch Block 9-4513

11 1 Pin, Mounting, Pinch Block 9-4521

12 1 Torch Holder Sleeve 7-2896

13 1 Pinion Assembly (does not include positioning tube) 7-2827


15 1 Pinion Gear-Short 8-6074

16 1 Handwheel (Torch Holder) 9-4514

17 1 Low Profile Torch Holder (1 3/8 Dia) w/o Hardware 9-4515

18 1 Calibrated Torch Holder Bushing 9-4366

19 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 1

20 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 1

21 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 1

22 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note 1

1 5" / 126 mm Positioning Tube (Not shown) 9-7042

Note 1: Item can be bought locally.


6

Art # A-03872

6

1

4

2

3

5

8

910

12

11

7

10

22

19

15

14

16

17

18

2021

21

13


6

6.12 Torch Replacement Parts

SL100SV Torch (with Solenoid on Mounting Tube)

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220

2 1 Large O - Ring 8-3487

3 1 Small O - Ring 8-3486

4 1 PIP Switch Kit 9-7036

5 1 PIP Plunger and Return Spring Kit 9-7045

6 Automated Leads Assemblies with ATC connectors




7 1 Rack 9-9448

8 1 Mounting Tube 9-9445

9 1 End Cap Assembly 9-7044

10 2 Body, Mounting, Pinch Block 9-4513

11 1 Pin, Mounting, Pinch Block 9-4521


13 1 Pinion Assembly (does not include positioning tube) 7-2827


15 1 Pinion Gear-Short 8-6074

16 1 Handwheel (Torch Holder) 9-4514

17 1 Low Profile Torch Holder (1 3/8 Dia) w/o Hardware 9-4515

18 1 Calibrated Torch Holder Bushing 9-4366

19 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 1

20 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 1

21 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 1

22 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note 1

23 1 Solenoid Assembly 9-9447

24 1 Solenoid Cover 9-9446

NOTE 1:

Purchase these parts locally.


6

Art # A-07113

6

1

4

2

3

5

8

10

12

11

7

10

22

19

15

14

16

17

18

2021

21

13

9

24 23


6

6.13 Torch Consumables

The illustration shows all SL100 torch consumable parts for use with the CutMaster 81 Automated PowerSupply.

Various front-end torch parts are available for different applications.

The Shield Cup Body with the Deflector Shield Cap provides extended parts life and improved resistance to reflectedheat.

The electrode and start cartridge are the same for all operations.

6.14 Torch Spare Parts Kits


40-Amp Automated Machine Torch Spare Parts Kit, includes: 5-00543 Electrode 9-82155 30 Amp Tip 9-82065 40 Amp Standoff Tip 9-82081 Start Cartridge 9-82131 Shield Cup Body 9-82371 Shield Cap, Machine, 40 Amp 9-82451 Shield Cap, Deflector 9-82431 Ohmic Clip Kit 9-82241 Large O - Ring 8-34871 Small O - Ring 8-3486

60-Amp Automated Machine Torch Spare Parts Kit, includes: 5-00791 Start Cartridge 9-82133 Electrode 9-82155 30 Amp Tip 9-82065 40 Amp Standoff Tip 9-82085 40 Amp Standoff Tip 9-82085 60 Amp Standoff Tip 9-82101 Shield Cup Body 9-82371 Shield Cap, Machine, 40 Amp 9-82451 Shield Cap, Machine, 50-60 Amp 9-82381 Shield Cap, Deflector 9-82431 Ohmic Clip Kit 9-82241 Large O - Ring 8-34871 Small O - Ring 8-3486


6

Art # A-04383

8-3487 8-3486

StartCartridge9-8213

Electrode9-8215


Shield Cap, Machine40A 9-8245

60A 9-8210

Tip:

Shield Cap, Machine50-60A 9-8238


Shield Cup Body,

9-8237

Tip:

Art # A-04216

20A 9-820530A 9-8206

40A 9-8208

Ohmic Clip9-8224

Torch Consumables Selection


6

6.15 Complete Torch Assembly Replacement


100 - Amp Machine Torch and Leads Assemblies, Unshielded Leads:

1 SL100 Machine Torch and 5 foot / 1.5 m Leads, with ATC Connector 7-5213

1 SL100 Machine Torch and 10 foot / 3.05 m Leads, with ATC Connector 7-52141 SL100 Machine Torch and 25 foot / 7.6 m Leads, with ATC Connector 7-5215



100 - Amp Machine Torch and Leads Assemblies, Unshielded Leads, with Solenoid:

1 SL100SV Machine Torch and 25 foot / 7.6 m Leads, with ATC Connector 7-40011 SL100SV Machine Torch and 35 foot / 10.6 m Leads, with ATC Connector 7-40021 SL100SV Machine Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-4003

6.16 Torch Options & Accessories


1 Computer Control (CNC) Cable25 Foot / 7.6 m length 8-555750 Foot / 15.2 m length 8-5558

1 Leather Leads Cover, 25 foot / 7.6 m length 9-1270

1 Leather Leads Cover, 50 foot / 15.2 m length 9-1280

1 Torch O-Ring Lubricant 8 - 4025


6

PATENT INFORMATION

The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512

Catalog Number Description

9-8235 Shield Cap, Drag 50-60A9-8236 Sheild Cap, Drag 70-100A9-8237 Shield Cup, Body9-8238 Shield Cap, Machine 50-60A9-8239 Shield Cap, Machine 70-100A9-8244 Shield Cap, Drag 40A9-8245 Shield Cap, Machine 40A


6


Manual 0-4641 A-1 APPENDIX

A

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM)

ACTION:

ON / OFF switch to ON

RESULT:

AC indicator ON. Fan(s) ON.

GAS indicator ON

when inputpressure is adequate

for power supply operation.Power circuit ready.

ACTION:

Protect eyes and activate torch.

RESULT:

Gas flows briefly, then stops.Gas restarts.

DC indicator ONPilot arc established.

Art #A-03706

ACTION:

Unplug inputpower cord or open externaldisconnect.

RESULT:

No power to system.

ACTION:

Connect work cable to workpiece. Set output amperage.

RESULT:

System is readyfor operation.

ACTION:

RUN / Rapid Auto Restart /

SET switch to SET

RESULT:

Gas flows to set pressure.

ACTION:RUN /

Rapid Auto Restart / SETswitch to RUN

(for most applications) or to

Rapid Auto Restart

(for gouging, trimming,or expanded metal

applications)RESULT:

Gas flow stops.

ACTION:

Release torch trigger.

RESULT:

Main arc stops.Gas flow stops after post - flow.

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.Power supply fan(s) shuts off.

ACTION:

Close externaldisconnect switch.

RESULT:

Power to system.

ACTION:

Torch moved within transfer distance of workpiece.

RESULT:

Main arc transfers.Pilot arc off.

PILOT ARC

ACTION:

Torch moved away from work (while still activated).

RESULT:

Main arc stops.Pilot arc automatically

restarts.

APPENDIX A-2 Manual 0-4641

A

APPENDIX 2: DATA TAG INFORMATION

1/3 ff12

West Lebanon, NH USA 03784

Made in USAModel:

U1 1 11max 1effI I

U2

3Ø 3Ø1Ø1Ø

S/N

U0 =

X

Standard Symbols

Ø

AC

DC

Phase

NOTES:1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectifier, DC output.2. Indicates input voltages for this power supply. Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built. 3. Top row: Duty cycle values. IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission. TDC duty cycle value is determined under the power supply manufacturer's test procedures. Second row: Rated cutting current values. Third row: Conventional load voltage values.4. Sections of the Data Tag may be applied to separate areas of the power supply.

I

Art # A-03288

Date of Mfr:

Output Range (Amperage/Voltage)

Type of PowerSupply (Note 1)

Output Current Type

Rated No-Load Voltage

Plasma Cutting Symbol

Manufacturer's Name and/orLogo, Location, Model andRevision Level, Serial Number and Production Code

ConventionalLoad Voltage

Regulatory Standard CoveringThis Type of Power Supply

Duty Cycle Data (Note 3)

Duty Cycle Factor

Input PowerSpecifications (Phase, AC or DCHertz Rating)

Input PowerSymbol

Rated Supply Voltage (Note 2)

Rated MaximumSupply Current

Maximum Effective Supply Current

Degree of Protection

Manufacturer's ElectricalSchematic File Numberand Revision Level


A

APPENDIX 3: MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the partslisted and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Check plasma and secondary supply and pressure/flow.

4. Purge plasma gas line to remove any moisture build-up.

5. Inspect input power cable for damage or exposed wires, replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interferewith sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.


A

APPENDIX 4: TORCH PIN - OUT DIAGRAMS

A. Power Supply and SL100 Torch (without Solenoid)

ATC Female Receptacle - Front View

ATC Male Connector - Front View

Negative / Plasma

Pilot

Negative / Plasma

6 - Open

7 - Open

5 - Open

8 - Open8 - Open

5 - White /Not Used

7 - Green /Not Used

56

78

12

3

4

Pilot

12

34

56

78

3 - Open

2 - Orange /PIP

1 - Black /PIP

4- Open

2 - PIP Circuit

1 - PIP Circuit

3 - Not Used

4 - Not Used

6 - Open

Art # A-03900

ATC Female Receptacle - Front View

ATC Male Connector - Front View

Negative / Plasma

Pilot

Negative / Plasma

6 - Open

7 - TorchSolenoid

5 - TorchSolenoid

8 - Open8 - Open

5 - White /- TorchSolenoid

7 - Green /- TorchSolenoid

56

78

12

3

4

Pilot

12

34

56

78

3 - Open

2 - Orange /PIP

1 - Black /PIP

4- Open

2 - PIP Circuit

1 - PIP Circuit

3 - Not Used

4 - Not Used

6 - Open

Art # A-07114

B. Power Supply and SL100SV Torch (with Solenoid)


A

APPENDIX 5: TORCH CONNECTION DIAGRAMS

A. Power Supply and SL100 Torch (without Solenoid)

Automated CutMaster Power Supply with ATC Torch Receptacle,Automated SL100 Torch with ATC Connector,

Power Supply

PIPSwitch

Not Used

ATC Male Torch Leads Connector

ATC Female Torch Receptacle

Black

Orange

Green

White

Negative / Plasma Lead

Pilot Lead

Art # A-03901

Pin No.sSocket

No.s1

2

5

43768

Torch LeadsTorch Head

No Signal

1

2

5

43768

Automated CutMaster Power Supply with ATC Torch Receptacle,Automated SL100SV Torch (w/ Solenoid on Positioning Tube), Torch Lead with ATC Connector

Power Supply

PIPSwitch

ATC Male Torch Leads Connector

ATC Female Torch Receptacle

Negative / Plasma Lead

Pilot Lead

Art # A-07115

Pin No.sSocket

No.s1

2

5

43768

Main PC Board

1

2

5

43768

White

Black

Orange

Green Main PC Board

Solenoid

Torch LeadsTorch Head

Not Connected

Not Connected

Main PC Board

Main PC Board

B. Power Supply and SL100SV Torch (with Solenoid)


A

APPENDIX 6: CONTROL CABLE PIN - OUT DIAGRAM

1 / Black

12 / White - Black / OK to Move

6 / Blue / (Positive) SC-11 Controller

7 / Yellow / Arc Volts (Negative)

11 / Gray

10 / Violet

AlignmentSplines

5 / Orange (Negative) SC-11 Controller

4 / Green / Torch Switch

8 / Logic Common

9 / Brown / Arc Volts (Positive)

AlignmentSplines

Art # A-03993

2 / White

13 - Open

14 / White - Red / OK to Move

AlignmentSpline

3 / Red / Torch Switch


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APPENDIX 7: INTERFACE PCB SWITCH SETTINGS(MOST COMMON SETTINGS)

1 2 3 4 5 6 7 8

0 0 0 0 0 0 0 0 6.00 12.00 16.3:1

0 0 0 1 0 1 1 0 5.00 10.00 20:10 1 0 1 0 0 0 1 3.3 6.6 30:11 1 0 0 0 0 0 0 2.5 5.0 40:11 1 1 1 1 1 1 1 2.0 4.0 50:1

0 = DOWN = OFF, 1 = UP = ON

Automation Interface Switch Setting Chart - Common Voltage Divider Output Settings


SW 4 SW3 SW2 SW1 Volts Outfor

100vdc In

Volts Outfor

200vdc In

Division Factor

Factory Default Settings Suitable for Thermal Dynamics SC-11 Standoff Control:

Other Common Settings:


A

Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor

0 0 0 0 0 0 0 0 16.560 0 0 0 0 0 0 1 16.700 0 0 0 0 0 1 0 16.840 0 0 0 0 0 1 1 16.980 0 0 0 0 1 0 0 17.140 0 0 0 0 1 0 1 17.280 0 0 0 0 1 1 0 17.420 0 0 0 0 1 1 1 17.560 0 0 0 1 0 0 0 17.740 0 0 0 1 0 0 1 17.890 0 0 0 1 0 1 0 18.030 0 0 0 1 0 1 1 18.170 0 0 0 1 1 0 0 18.320 0 0 0 1 1 0 1 18.460 0 0 0 1 1 1 0 18.600 0 0 0 1 1 1 1 18.750 0 0 1 0 0 0 0 19.110 0 0 1 0 0 0 1 19.250 0 0 1 0 0 1 0 19.390 0 0 1 0 0 1 1 19.530 0 0 1 0 1 0 0 19.690 0 0 1 0 1 0 1 19.830 0 0 1 0 1 1 0 19.970 0 0 1 0 1 1 1 20.110 0 0 1 1 0 0 0 20.290 0 0 1 1 0 0 1 20.440 0 0 1 1 0 1 0 20.580 0 0 1 1 0 1 1 20.720 0 0 1 1 1 0 0 20.870 0 0 1 1 1 0 1 21.010 0 0 1 1 1 1 0 21.150 0 0 1 1 1 1 1 21.300 0 1 0 0 0 0 0 21.670 0 1 0 0 0 0 1 21.810 0 1 0 0 0 1 0 21.950 0 1 0 0 0 1 1 22.090 0 1 0 0 1 0 0 22.250 0 1 0 0 1 0 1 22.390 0 1 0 0 1 1 0 22.530 0 1 0 0 1 1 1 22.670 0 1 0 1 0 0 0 22.850 0 1 0 1 0 0 1 23.000 0 1 0 1 0 1 0 23.140 0 1 0 1 0 1 1 23.280 0 1 0 1 1 0 0 23.430 0 1 0 1 1 0 1 23.570 0 1 0 1 1 1 0 23.710 0 1 0 1 1 1 1 23.86

Automation Interface Switch Setting Chart - Division Factors 16 - 24



APPENDIX 8: INTERFACE PCB SWITCH SETTINGS(Division Factors 16-24)


A



0 0 1 1 0 0 0 0 24.220 0 1 1 0 0 0 1 24.360 0 1 1 0 0 1 0 24.500 0 1 1 0 0 1 1 24.640 0 1 1 0 1 0 0 24.800 0 1 1 0 1 0 1 24.940 0 1 1 0 1 1 0 25.080 0 1 1 0 1 1 1 25.220 0 1 1 1 0 0 0 25.400 0 1 1 1 0 0 1 25.550 0 1 1 1 0 1 0 25.690 0 1 1 1 0 1 1 25.830 0 1 1 1 1 0 0 25.980 0 1 1 1 1 0 1 26.120 0 1 1 1 1 1 0 26.260 0 1 1 1 1 1 1 26.410 1 0 0 0 0 0 0 27.320 1 0 0 0 0 0 1 27.460 1 0 0 0 0 1 0 27.600 1 0 0 0 0 1 1 27.740 1 0 0 0 1 0 0 27.890 1 0 0 0 1 0 1 28.040 1 0 0 0 1 1 0 28.180 1 0 0 0 1 1 1 28.320 1 0 0 1 0 0 0 28.500 1 0 0 1 0 0 1 28.650 1 0 0 1 0 1 0 28.780 1 0 0 1 0 1 1 28.930 1 0 0 1 1 0 0 29.080 1 0 0 1 1 0 1 29.221 0 0 0 0 0 0 0 29.310 1 0 0 1 1 1 0 29.361 0 0 0 0 0 0 1 29.450 1 0 0 1 1 1 1 29.501 0 0 0 0 0 1 0 29.591 0 0 0 0 0 1 1 29.730 1 0 1 0 0 0 0 29.871 0 0 0 0 1 0 0 29.89

Automation Interface Switch Setting Chart, Division Factors 24-30




A



0 1 0 1 0 0 0 1 30.011 0 0 0 0 1 0 1 30.030 1 0 1 0 0 1 0 30.151 0 0 0 0 1 1 0 30.170 1 0 1 0 0 1 1 30.291 0 0 0 0 1 1 1 30.310 1 0 1 0 1 0 0 30.441 0 0 0 1 0 0 0 30.490 1 0 1 0 1 0 1 30.591 0 0 0 1 0 0 1 30.640 1 0 1 0 1 1 0 30.731 0 0 0 1 0 1 0 30.780 1 0 1 0 1 1 1 30.871 0 0 0 1 0 1 1 30.920 1 0 1 1 0 0 0 31.051 0 0 0 1 1 0 0 31.070 1 0 1 1 0 0 1 31.201 0 0 0 1 1 0 1 31.210 1 0 1 1 0 1 0 31.331 0 0 0 1 1 1 0 31.350 1 0 1 1 0 1 1 31.481 0 0 0 1 1 1 1 31.500 1 0 1 1 1 0 0 31.630 1 0 1 1 1 0 1 31.771 0 0 1 0 0 0 0 31.860 1 0 1 1 1 1 0 31.911 0 0 1 0 0 0 1 32.000 1 0 1 1 1 1 1 32.051 0 0 1 0 0 1 0 32.141 0 0 1 0 0 1 1 32.280 1 1 0 0 0 0 0 32.431 0 0 1 0 1 0 0 32.440 1 1 0 0 0 0 1 32.571 0 0 1 0 1 0 1 32.580 1 1 0 0 0 1 0 32.711 0 0 1 0 1 1 0 32.720 1 1 0 0 0 1 1 32.851 0 0 1 0 1 1 1 32.86





A



0 1 1 0 0 1 0 0 33.011 0 0 1 1 0 0 0 33.040 1 1 0 0 1 0 1 33.151 0 0 1 1 0 0 1 33.190 1 1 0 0 1 1 0 33.291 0 0 1 1 0 1 0 33.330 1 1 0 0 1 1 1 33.431 0 0 1 1 0 1 1 33.470 1 1 0 1 0 0 0 33.611 0 0 1 1 1 0 0 33.620 1 1 0 1 0 0 1 33.761 0 0 1 1 1 0 1 33.760 1 1 0 1 0 1 0 33.891 0 0 1 1 1 1 0 33.900 1 1 0 1 0 1 1 34.041 0 0 1 1 1 1 1 34.050 1 1 0 1 1 0 0 34.190 1 1 0 1 1 0 1 34.331 0 1 0 0 0 0 0 34.420 1 1 0 1 1 1 0 34.471 0 1 0 0 0 0 1 34.560 1 1 0 1 1 1 1 34.611 0 1 0 0 0 1 0 34.701 0 1 0 0 0 1 1 34.840 1 1 1 0 0 0 0 34.981 0 1 0 0 1 0 0 35.000 1 1 1 0 0 0 1 35.121 0 1 0 0 1 0 1 35.140 1 1 1 0 0 1 0 35.261 0 1 0 0 1 1 0 35.280 1 1 1 0 0 1 1 35.401 0 1 0 0 1 1 1 35.420 1 1 1 0 1 0 0 35.561 0 1 0 1 0 0 0 35.600 1 1 1 0 1 0 1 35.701 0 1 0 1 0 0 1 35.750 1 1 1 0 1 1 0 35.841 0 1 0 1 0 1 0 35.890 1 1 1 0 1 1 1 35.98

Automation Interface Switch Setting Chart, Division Factors 33 - 36




A



1 0 1 0 1 0 1 1 36.030 1 1 1 1 0 0 0 36.161 0 1 0 1 1 0 0 36.180 1 1 1 1 0 0 1 36.311 0 1 0 1 1 0 1 36.320 1 1 1 1 0 1 0 36.441 0 1 0 1 1 1 0 36.460 1 1 1 1 0 1 1 36.591 0 1 0 1 1 1 1 36.610 1 1 1 1 1 0 0 36.740 1 1 1 1 1 0 1 36.881 0 1 1 0 0 0 0 36.970 1 1 1 1 1 1 0 37.021 0 1 1 0 0 0 1 37.110 1 1 1 1 1 1 1 37.161 0 1 1 0 0 1 0 37.251 0 1 1 0 0 1 1 37.391 0 1 1 0 1 0 0 37.551 0 1 1 0 1 0 1 37.691 0 1 1 0 1 1 0 37.831 0 1 1 0 1 1 1 37.971 0 1 1 1 0 0 0 38.151 0 1 1 1 0 0 1 38.301 0 1 1 1 0 1 0 38.441 0 1 1 1 0 1 1 38.581 0 1 1 1 1 0 0 38.731 0 1 1 1 1 0 1 38.871 0 1 1 1 1 1 0 39.011 0 1 1 1 1 1 1 39.161 1 0 0 0 0 0 0 40.071 1 0 0 0 0 0 1 40.211 1 0 0 0 0 1 0 40.351 1 0 0 0 0 1 1 40.491 1 0 0 0 1 0 0 40.641 1 0 0 0 1 0 1 40.791 1 0 0 0 1 1 0 40.931 1 0 0 0 1 1 1 41.071 1 0 0 1 0 0 0 41.251 1 0 0 1 0 0 1 41.401 1 0 0 1 0 1 0 41.531 1 0 0 1 0 1 1 41.681 1 0 0 1 1 0 0 41.831 1 0 0 1 1 0 1 41.971 1 0 0 1 1 1 0 42.111 1 0 0 1 1 1 1 42.251 1 0 1 0 0 0 0 42.621 1 0 1 0 0 0 1 42.761 1 0 1 0 0 1 0 42.90





A



1 1 0 1 0 0 1 1 43.041 1 0 1 0 1 0 0 43.191 1 0 1 0 1 0 1 43.341 1 0 1 0 1 1 0 43.481 1 0 1 0 1 1 1 43.621 1 0 1 1 0 0 0 43.801 1 0 1 1 0 0 1 43.951 1 0 1 1 0 1 0 44.081 1 0 1 1 0 1 1 44.231 1 0 1 1 1 0 0 44.381 1 0 1 1 1 0 1 44.521 1 0 1 1 1 1 0 44.661 1 0 1 1 1 1 1 44.801 1 1 0 0 0 0 0 45.181 1 1 0 0 0 0 1 45.321 1 1 0 0 0 1 0 45.461 1 1 0 0 0 1 1 45.601 1 1 0 0 1 0 0 45.761 1 1 0 0 1 0 1 45.901 1 1 0 0 1 1 0 46.041 1 1 0 0 1 1 1 46.181 1 1 0 1 0 0 0 46.361 1 1 0 1 0 0 1 46.511 1 1 0 1 0 1 0 46.641 1 1 0 1 0 1 1 46.791 1 1 0 1 1 0 0 46.941 1 1 0 1 1 0 1 47.081 1 1 0 1 1 1 0 47.221 1 1 0 1 1 1 1 47.361 1 1 1 0 0 0 0 47.731 1 1 1 0 0 0 1 47.871 1 1 1 0 0 1 0 48.011 1 1 1 0 0 1 1 48.151 1 1 1 0 1 0 0 48.311 1 1 1 0 1 0 1 48.451 1 1 1 0 1 1 0 48.591 1 1 1 0 1 1 1 48.731 1 1 1 1 0 0 0 48.911 1 1 1 1 0 0 1 49.061 1 1 1 1 0 1 0 49.191 1 1 1 1 0 1 1 49.341 1 1 1 1 1 0 0 49.491 1 1 1 1 1 0 1 49.631 1 1 1 1 1 1 0 49.771 1 1 1 1 1 1 1 49.91

Automation Interface Switch Setting Chart, Division Factors 43 - 50




A

APPENDIX 14: AUTOMATION INTERFACE PC BOARDWIRING LAYOUT

J-1


Pilot Board

8 7 6 5 4 3 2 1

321

E1

E3

Art # A-03589

Rear Panel CPC Connector

Automation InterfacePCB Connector J1

INPUTDIODE

E6

E5Main PC Board

Automation InterfacePCB Connector J4

CSR

OutputDiodes

Output Power Board

Hooks for Raw Arc Voltage

To Ground Stud

TS2

TS1

NEG


A

APPENDIX 15: AUTOMATION INTERFACE PC BOARDLAYOUT and TEST POINTS

TP1 TP3TP2TP4

Art # A-03903

J1

J4

J2

J3

Signals

Connector J2 (To wiring harness for alternate

CNC Controller)

J2-1 Torch Switch (Positive)J2-2 OpenJ2-3 Torch Switch (Negative)J2-4 OpenJ2-5 OK to MoveJ2-6 OpenJ2-7 OK to MoveJ2-8 OpenJ2-9 Divided Output (Positive)J2-10 OpenJ2-11 Divided Output (Negative)J2-12 OpenJ2-13 Remote Current ControlJ2-14 Remote Current ControlJ2-15 Remote Current ControlJ2-16 OpenJ2-17 DC CommonJ2-18 Arc Volts (+)J2-19 OpenJ2-20 Arc Volts (-)

Connector J4 (to CPC Connector on Power Supply Rear Panel)

J4-1 Arc Volts (-) (Through 100K ohm resistor)J4-2 OpenJ4-3 Arc Volts (+) (Through 100K ohm resistor)J4-4 Logic CommonJ4-5 OpenJ4-6 OpenJ4-7 OpenJ4-8 OpenJ4-9 OpenJ4-10 SC-11 (-)J4-11 OpenJ4-12 SC-11 (+)J4-13 OpenJ4-14 OK to MoveJ4-15 OpenJ4-16 OK to MoveJ4-17 OpenJ4-18 Torch Switch (-)J4-19 OpenJ4-20 Torch Switch (+)


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APPENDIX 16: AUTOMATION INTERFACE PC BOARDWIRING CONNECTIONS TO OEM CNC HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Art # A-04148

Torc

h Switc

h (P

ositiv

e)

t

o CPC H

ousin

g, P

in 4

Torc

h Switc

h (N

egat

ive)

to C

PC Hou

sing,

Pin

3

OK to M

ove

to

CPC Hou

sing,

Pin

14

OK to M

ove

to C

PC Hou

sing,

Pin

12

Divide

d Out

put (

Positiv

e) t

o CPC H

ousin

g, P

in 6

Divide

d Out

put (

Negat

ive)

to C

PC Hou

sing,

Pin

5

Logic

Com

mon

to C

PC Hou

sing,

Pin

8

Open

Open

Open

Open

Open

Open

Open

Open

Arc Vo

lts (P

ositiv

e) to

CPC H

ousin

g, P

in 9

Arc Vo

lts (

Negat

ive) t

o CPC H

ousin

g, P

in 7

Open

Open

Open





Terminal Block J4



A

APPENDIX 17: AUTOMATION INTERFACE PC BOARDWIRING CONNECTIONS TO ALTERNATE CNC HARNESS

39 5 4 12678101319 15 14 111216171820

Art # A-04149

Torc

h Switc

h

(Pos

itive)

Torc

h Switc

h (N

egat

ive)

OK to M

ove

OK to M

ove

Divide

d Out

put (

Positiv

e)

Divide

d Out

put (

Negat

ive)

Logic

Com

mon

Open

Open

Open

Open

Open

Open

Open

Open

Arc V

olts -

Pos

itive

(Pro

priet

ary)

Arc V

olts

Negat

ive -

(Pro

priet

ary)

Remot

e Cur

rent

Con

trol (

Option

al)

Remot

e Cur

rent

Con

trol (

Option

al)

Remot

e Cur

rent

Con

trol (

Option

al)





Terminal Block J2

E2 (+)E1(-)


Output Power PC Board

Raw Arc Voltage Connection Points


A

APPENDIX 18: MAIN PC BOARD LAYOUT

Art # A-03651

INPUTDIODE

E22

E1

E2

E3

TP1

E7

E15

TP4 U1 J24 J32 J29

E10

E20

E4 J30E33

J18

J26

E27

J23

E30

J33

J31 E23

E32

J27

J25

IGBT A IGBT B

J43

J34

J11

J15

J16

J17

E6

E5

FUSE

Main Power PC Board Signals

J11-1 L1 InputJ11-4 L3 Input

J15-1 Fan (M1)J15-2 Fan (M1)J15-3 Not usedJ15-4 Not usedJ15-5 Fan (M2)J15-6 Fan (M2)

J16-1 Not usedJ16-2 Not used

J17-1 Not usedJ17-2 Not used

J18-1 Not usedJ18-2 Not usedJ18-3 28 VAC BJ18-4 28 VAC AJ18-5 On-Off SwitchJ18-6 On-Off SwitchJ18-7 Run-Set SwitchJ18-8 Run-Set Switch

J23-1 Not usedJ23-2 Not usedJ23-3 Not used

J24-1 Gas Solenoid (SOL1)J24-2 Gas Solenoid (SOL1)J24-3 Pressure Switch (PS1)J24-4 Pressure Switch (PS1)J24-5 Main Contactor (W1)J24-6 Main Contactor (W1)J24-7 Not usedJ24-8 Not used


A

J25-1 Gate DriveJ25-2 Gate Drive

J26-1 Gate DriveJ26-2 Gate DriveJ27-1 Pot HighJ27-2 Pot WiperJ27-3 Pot LowJ27-4 +12VJ27-5 ACJ27-6 GasJ27-7 OvertempJ27-8 DC

J29-1 IGBT Heatsink TempJ29-2 IGBT Heatsink TempJ29-3 JumperJ29-4 Jumper



J32-1 Inductor Temp SwitchJ32-2 Inductor Temp Switch

J33-1 - Out SenseJ33-2 DC ComJ33-3 Tip SenseJ33-4 + 12 vdcJ33-5 CSRJ33-6 I SenseJ33-7 Not usedJ33-8 Tip voltsJ34-1 PIP ReturnJ34-2 PIPJ34-3 Not usedJ34-4 Not usedJ34-5 Torch Switch ReturnJ34-6 Torch Switch

J43-1 + 12 vdc to Logic PCBJ43-2 + 12 vdc to Logic PCBJ43-3 DC ComJ43-4 DC ComJ43-5 MC1 OnJ43-6 Tip SenseJ43-7 Run / SetJ43-8 Pressure GoodJ43-9 OvertempJ43-10 CSRJ43-11 Gas onJ43-12 DC OKJ43-13 OVTEMPJ43-14 AC OKJ43-15 Torch SwitchJ43-16 Torch Switch ReturnJ43-17 + 12 vdcJ43-18 POT HighJ43-19 POT WiperJ43-20 POT LowJ43-21 Gate Drive B ReturnJ43-22 Gate Drive BJ43-23 Gate Drive A ReturnJ43-24 Gate Drive AJ43-25 - Out SenseJ43-26 Current SenseJ43-27 Current SenseJ43-28 Current Sense ReturnJ43-29 Current Sense ReturnJ43-30 DC ComJ43-31 DC ComJ43-32 Not UsedJ43-33 I SenseJ43-34 Not UsedJ43-35 Not UsedJ43-36 Tip Volts

TP1 GroundTP4 +12 vdc


A

APPENDIX 19: MAIN PC BOARD WIRING LAYOUT(208 /230-Volt POWER SUPPLIES)

INPUTDIODE

E2

E3

E1

Art # A-04224

To InputContactor

To Chassis Ground

To Logic Boardvia Connector

To Power Output Board

To TorchConnector

To On/Off andRun/Rapid RestartSet SwitchesTo Fans

To MainInput Contactor

Test Connector To Heat SinkTemp Sensor

Heat SinkTemp Sensor

To Inductor Temp SensorTo Press Switch/Solenoid/Contactor

Fuse

SecondaryTransformer

Copper Strap

#1

To InputContactor

To Auto InterfaceBoard J1-5


To MainTransformer

#33

#78#1

LT1

#32

#27

#2

#3

To POT/LED PCB (or to

Optional RemoteCurrent Control )*

* If installed in conjuction with Automation Interface PC Board

J30 J31

Logic Board Not Shown


A

APPENDIX 20: MAIN PC BOARD WIRING LAYOUT (400-Volt, 415-Volt, 460-Volt, 600-Volt POWER SUPPLIES)

INPUTDIODE

Art # A-04225

#2#3

#1To InputContactor

To Chassis Ground To Torch

ConnectorTo FansTo MainInput Contactor

TestConnector

Heat SinkTemp Sensor

To Inductor Temp SensorTo Press Switch/Solenoid/Contactor

Fuse

SecondaryTransformer

To MainTransformer

To Logic Boardvia Connector

To Power OutputBoard

To On/Off andRun/Rapid RestartSet Switches

To Heat SinkTemp Sensor



To POT/LED PCB (or to

Optional RemoteCurrent Control )*

* If installed in conjuction with Automation Interface PC Board

#32

#27

LT1

J30 J31


A

APPENDIX 21: LOGIC BOARD LAYOUT

TP9

TP10

TP11

TP3

TP7TP8TP5

TP1

TP2

TP4

D13 TP6

Art # A-03654D25

D33

P1-7

P1-9

Logic Board Signals

P1-1 +12vdcfrom Main Power PCBP1-2 +12vdcfrom Main PCBP1-3 DC ComP1-4 DC ComP1-5 MC1 ON signalP1-6 Tip SenseP1-7 RUN/SET Signal Logic Low for SETP1-8 Logic Low = PS1 Pressure Switch

closed = Pressure OKP1-9 Logic Low = TS1 Closed = OVERTEMPP1-10 Logic Low = CSRP1-11 Logic Low = Gas ONP1-12 Logic Low = DC OKP1-13 Logic Low = OVTEMPP1-14 Logic Low = AC OKP1-15 Logic Low = Torch SwitchP1-16 Logic Low = Torch Switch ReturnP1-17 Logic Low = +12vdcP1-18 Logic Low = Pot HighP1-19 Logic Low = Pot HighP1-20 Pot LowP1-21 Gate Drive B ReturnP1-22 Gate Drive BP1-23 Gate Drive A ReturnP1-24 Gate Drive AP1-25 - Out SenseP1-26 Current Sense

P1-27 Current SenseP1-28 Current Sense ReturnP1-29 Current Sense ReturnP1-30 DC ComP1-31 DC ComP1-32 Not UsedP1-33 I SenseP1-34 Not UsedP1-35 Not UsedP1-36 TipVolts

INDICATORS:D13 INV OND25 DRAG OND33 SWITCH ON

TEST POINTS:TP-1 CommonTP-2 Current Demand SignalTP-3 Converter EnableTP-4 CSR (Logic Low)TP-5 Not usedTP-6 Fault (Logic Low)TP-7 DC OK (Logic Low)TP-8 Tip SenseTP-9 Current SenseTP-10 Gate Drive ATP-11 Gate Drive B


A

APPENDIX 22: POT / LED BOARD LAYOUT

J14

D4

D5

D7

D6

A-03712

Pot/LED PC Board Signals

J14-1 from Main PC Board (J27-1) Pot HighJ14-2 Main PC Board (J27-2) Pot WiperJ14-3 from Main PC Board (J27-3) Pot LowJ14-4 12vdc (J27-4)J14-5 Logic Low Signal for AC OK Indicator from Logic PC Board (J27-5)J14-6 Logic Low Signal for GAS Indicator from Logic PC Board (J27-6)J14-7 Logic Low Signal for TEMP Indicator from Logic PC Board (J27-7)J14-8 Logic Low Signal for DC Indicator from Logic PC Board (J27-8)

D4 Front Panel AC IndicatorD5 Front Panel TEMP IndicatorD6 Front Panel GAS IndicatorD7 Front Panel DC Indicator


A

APPENDIX 23: OUTPUT BOARD WIRING DIAGRAM

Art # A-04382

E36

OutputDiode A

OutputDiode B

E32

To Output Inductor

E45

E49

E61

Work Cable

E57E58E43 To OutputInductor

E52

E35 E62

To Torch To Pilot PCB To Main PCB To Pilot PCB

J39 J40E37Chassis Ground

To Trans-former

To Trans-former

TP1

To Torch

E64

To PilotBoard

E47

Raw Arc Voltage Connections

E1 (-) E2 (+)


A

APPENDIX 24: OUTPUT DIODE BOARD LAYOUT

A-03152

E48

E50

E54

E53

E34

E39

E60

E56

Output Diode A Output Diode B

E34

E39

E60

E56

E48

E50

E54

E53


A

APPENDIX 25: PILOT BOARD LAYOUT

Pilot Board Signals

J1-1 +12 vdc to Automation Interface PC Board J1-3J1-2 DC Common to Automation Interface PC Board J1-2

J28-1 +12 vdcJ28-2 DC ComJ28-3 Not UsedJ28-4 Not UsedJ28-5 Logic Low CSRJ28-6 Not UsedJ28-7 Not UsedJ28-8 Not Used

E58 To Power Output PC Board Terminal E58E62 To Power Output PC Board Terminal E62

J28

Heatsink

To Automation InterfaceBoard Connector J1

Art # A-04218

J1


A

APPENDIX 26: 28VAC CIRCUIT DIAGRAM

1 2 5 6

3 4 5 6

Main Power PC Board

AuxiliaryTransformer

VoltageProtectionCRT/+12 Regulator

J18

J24

+12vdc

W1SOL

ON/OFF Switch

A-03710

primary

seco

ndar

y

Fuse

23

J23 (Test)

K5

K4

J81 4

Line Voltage

J11

1


A

APPENDIX 27: INPUT DIODE LAYOUT

Art # A-03703

E18 E13 E5

E14 E16 E8 E6

19x1811


A



A

APPENDIX 28: 208/230V SYSTEM SCHEMATIC

For Power Supplies and SL100 Torches (without solenoid on mounting tube)

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18V

+18V

208/230V1 PHASEINPUT

2

1

(5)

(3)

2

SE

C

2

2

MAIN BOARDASSY 19X1912

2

ON/OFF SW

CHASSIS GND

1

CURRENTCONTROL/LED PCB19X1604

1

W1

1

(1)

1

(4)

PR

I

(2)

CURRENT ADJUST:20 - 80 FOR CM10120 - 60 FOR CM81

IGBTHEATSINKTEMP

INDUCTORTEMP

P11 J11

INPUT DIODEASSY 19X2073

MAIN TRANSFORMER

J7B

J3B

J7A

J3A

P3B

P7B

P3A

P7A

E22

TESTCONN

GASSOLENOID

PRESSURESWITCH

MAINCONTACTOR

T5

PR

I

SE

C

L1

L2

L3

L4(78)

COPPER STRAP

212223

POT LOWGATE DRIVE B RTN

GATE DRIVE BGATE DRIVE A RTN

GATE DRIVE A- OUT SENSE

CURRENT SENSE

CURRENT SENSE RTN

TIP VOLTS

+12V

TORCH SW

PRESS GOOD

POT WIPER

RUN/SETTIP SENSE

CSR

2425262728293031

ISENSE3233

CURRENT SENSE RTN

343536

CURRENT SENSE

OVERTEMP

OVTEMP

+12VDC

DC OK

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

POT HIGH

+12VDC

AC OK

DC COM

TORCH SW RTN

4

EXTENDER

5

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

21222324252627282930313233343536

45

3

6

12

9

15

10

14

16

13

1920

1718

11

8

12

D13

7

D33

ASSY 19X1913 - CM101

DC COMW1 ON

D25GAS ON

DC COMDC COM

P13 J12P1

INV ON

DRAG ON

SW ON

ASSY 19X1775

LOGIC

ASSY 19X1932 - CM81

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

TS2

P32 J321

21

2

P29

NTC

1234

1

4

23

J29

TS1

TEMP

AC

P14 P27 J27J14

8

67

4

1

5

23

(36)

(38)(37)

8

65

23

1

4

78

3

5

2

7

1

4

6

(35)

GAS

(41)(40)(39)

(42) 8

67

1

45

23

+12VPOT LOW

OVERTEMP

POT WIPERPOT HIGH

DC

GASAC

DC

(25)(24)

28VAC B

SET

(21)

RUN

(22)28VAC A(23)

SW1

SW2

(26) 8

3

5

2

7

1

4

6

8

67

1

45

23

P18 J18

230V

(6)(6)

(7)230V (7)

3

5

21

4

6 6

1

45

23

FAN1

FAN2

M1

M2

P15 J15

21

34

21

34

W1

W1

W1

P24

W1

PS1

SOL1BA

8

3

5

2

7

1

4

6

J24

8

67

1

45

23

(12)(13)

(11)(10)

(8)(9)

J23

321

3PIP

5

21

4

6 6

1

45

23

TORCH SWTORCH SW RTN

8

PIPPIP RTN

2

TORCH SW

(78)(79)

(80)(81)

J34 P341

43

3

87

2

54

1

6

8

4

76

2

5

1

3DC COM

+12VDC

TIP VOLTS

-OUT SENSE

I SENSE

TIP SENSE

CSR

(71)

(77)

(70)

(73)(74)(75)

(72)

8

2

5

3

1

76

4

76

8

54

1

32

P33J33 J39P39

P26

J25

J30

J31

J26 12

12

12

12 2

P25

P30

P31

21

21

21

1

E5

E13

E18

E6E8

E14E16

E15

E7

E4

E23

E20

E30

E10

E27

E32

GATEDRIVE

GATEDRIVE

GATEDRIVE

GATEDRIVE

E12A

E17A

E19A

E21A

E9A

E11A

E9B

E11B

E19B

E21B

E12B

E17B

IGBT BOARDASSY 19X1756


E52 E47

2

1

2

1

2

1

E5E6

(STANDARD)

ATC CONNECTIONCONFIGURATION

(FILTERING)

28VAC B28VAC A

R30

F1T1

K1K1

28VAC A28VAC B

28VAC A

28VAC BGND

TO BIAS SUPPLY

FAN

INRUSH

K1

K2

F2, 0.9A,(RESETABLE)

K4

K5

CONTACTOR ON

K5

SOLENOID ON

K4

PRESS GOOD

8

21

43

ATC RECEIVERATC MALE CONNECTOR

CLOSED WHENPRESSURE OK

(33)

SENSECURRENT

MODE SW

RAR OFF(46)

(6/10A 600V)

(0 ohm)

K2

J43

(PILOT PCB)(F9)

(TS1)(TS2)

E1E1

24

12

23

1314

2527

24567

1

28

24

12

23

1314

2527

24567

1

28

E33E33 E3E3

tt

E2E2

Art # A-06753


A

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References

DateByRevisionsRev PCB No:Assy No:

Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.Capacitors are in Microfarads (UF) Chk: App:

TITLE:Last Modified:

SizeSCHEMATIC,42X1136Tuesday, March 22, 2005

1 1

INDUSTRIAL PARK No. 2WEST LEBANON, NH 03784603-298-5711

CM81/101 208/230V SYSTEM11:05:29

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 208/230V SYSTEM11:05:29

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 208/230V SYSTEM11:05:29

THERMAL DYNAMICS

D

OUTPUT DIODEASSEMBLY19X1757

THRU SCREW TERMINAL

PILOT


CHASSISGND

COMP DESCRIPTION LOCATION

D.Lilja

CURRENT

L1

DC COMMON DC COMMON

OUTPUT INDUCTOR

NOTES: UNLESS OTHERWISE SPECIFIED -

IS FOR REFERENCE ONLY

(REL) DLL 05/07/03

SENSE

POWER OUTPUT BOARD ASSY 19X1914

E50AE48A

E53AE54A

E56AE60A

E39A

E34A

E37 E58

DC COM

ISENSE

+12VDCJ40

5

3

76

4

8

21

CSR

1

5

7

3

P40

2

(18)8

4 (17)

(15)(14)

6

(E58)

J28

2

PILOT BOARD

E62

8

1

E58

ASSY 19X2157

5

E49 E45 E35 E61E32

E64E43E62

E36 E57

E63

E34B

E39B

E56BE60B

E50BE48B

E53BE54B

(E62)

(E35)

WORK

TORCH

(E64)(E64)

L1

W1

F1F2

M1M2

TS1TS2

FUSE, 6/10A 600V KTK

MAIN CONTACTOR

OUTPUT INDUCTOR

TEMP. SENSOR, INDUCTORTEMP. SENSOR, IGBT HEATSINKMAIN TRANSFORMER

FAN, 4.5" 220VAC

FUSE, 0.9A, RESETABLE

SWITCH, ON/OFFGAS SOLENOIDPRESSURE SWITCHFAN, 4.5" 220VAC

SWITCH, RUN/SET/RAR

F4

D7B1C1F4F4

C1

E1D1

JUMPER

5897

OK TO MOVE(+)(-)

LOGIC COMMON(+)(-) ARC VOLTS (C&G)

(+)(-) TORCH SWITCH

INTERFACE

Vo

54

6

1

7

23

8

1817

1920

13

10

16

14

9

15

1211

P4

PLUGS INTO J27ON MAIN BOARD*

J2

J1

ALTERNATE 20-PIN HEADER

45

8

23

1

67

20-POSITION TERMINAL STRIP

54

3

54

6

1

7

23

8

67

19

13

10

16

14

9

15

1211

1817

1817

1920

13

10

16

14

9

15

1211

8

21

20

J4

J3

45

23

8

1

67

45

8

32

7

1

OPTIONAL

6

19X2041

TORCH SW -TORCH SW +

DC COMMON+12VDC

CSRP1

OK TO MOVE

+-

AUTOMATION

+-

TORCH SWITCH

SC-11

P3

DC

GAS

AC

TEMP

(LED PCB 19X1604)

J14 P14

7

1

6

32

8

45

1

5

8

4

67

23 3

21 1

23

+-

DC COMMON

DIVIDED OUTPUT

REMOTE CURRENT CONTROL

C&G

CPCHOUSING

4

143

126

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS

CSR Vo

E3 E1

}}}

}

C1

D4T5

PS1SOL1

SW2SW1

F3B2

ECO 101136

RAR OFF

3(46)

(47)(48)(49)

(51)(52)

(TS2)(TS1)

(NEG)

(56)(57)

(58)(59)

(60)(61)

(62)(63)

(64)

12

(52)(51)

J1

HAS 02/11/04ECO 101314ABECO 101429 HAS 06/09/04AC

CONTROL IS USED WITHWHEN REMOTE CURRENT

(REPLACES CONNECTIONSAUTOMATION

ADAPTER HARNESS USED

FROM J27 TO J14)

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

05/07/03

ATC MALE CONNECTORATC RECEIVER

(C1)(MODE SW)

(CSR)

(CSR) (NEG)

AA

ECO 101614AD HAS 03/22/05

Art # A-06753


A

APPENDIX 29: 208/230V SYSTEM SCHEMATIC

For Power Supplies and SL100SV Torches (with solenoid on mounting tube)1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18V

+18V

208/230V1 PHASEINPUT

2

1

(5)

(3)

2

SE

C

2

2


2

ON/OFF SW

CHASSIS GND

1


1

W1

1

(1)

1

(4)

PR

I

(2)


IGBTHEATSINKTEMP

INDUCTORTEMP

P11

J11


MAIN TRANSFORMER

J7B

J3B

J7A

J3A

P3B

P7B

P3A

P7A

E22

TESTCONN

GASSOLENOID

PRESSURESWITCH

MAIN CONTACTOR

T5

PR

I

SE

C

L1

L2

L3

L4(78)

COPPER STRAP

212223




CURRENT SENSE

CURRENT SENSE RTN

TIP VOLTS

+12V

TORCH SW

PRESS GOOD

POT WIPER

RUN/SETTIP SENSE

CSR

2425262728293031

ISENSE3233

CURRENT SENSE RTN

343536

CURRENT SENSE

OVERTEMP

OVTEMP

+12VDC

DC OK

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

POT HIGH

+12VDC

AC OK

DC COM

TORCH SW RTN

4

EXTENDER

5

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

21222324252627282930313233343536

45

3

6

12

9

15

10

14

16

13

1920

1718

11

8

12

D13

7

D33

ASSY 19X2285 - CM101

DC COMW1 ON

D25GAS ON

DC COMDC COM

P13 J12P1

INV ON

DRAG ON

SW ON

ASSY 19X1775

ASSY 19X2284 - CM81 45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

TS2

P32 J321

21

2

P29

NTC

1234

1

4

23

J29

TS1

TEMP

AC

P14 P27 J27J14

8

67

4

1

5

23

(36)

(38)(37)

8

65

23

1

4

78

3

5

2

7

1

4

6

(35)

GAS

(41)(40)(39)

(42) 8

67

1

45

23

+12VPOT LOW

OVERTEMP

POT WIPERPOT HIGH

DC

GASAC

DC

(25)(24)

28VAC B

SET

(21)

RUN

(22)28VAC A(23)

SW1

SW2

(26) 8

3

5

2

7

1

4

6

8

67

1

45

23

P18 J18

230V

(6)(6)

(7)230V (7)

3

5

21

4

6 6

1

45

23

FAN1

FAN2

M1

M2

P15 J15

21

34

21

34

W1

W1

W1

P24

W1

PS1

SOL1BA

8

3

5

2

7

1

4

6

J24

8

67

1

45

23

(12)(13)

(11)(10)

(8)(9)

J23

321

3PIP

5

21

4

6 6

1

45

23


8

PIPPIP RTN

2

TORCH SW

(78)(79)

(80)(81)

J34 P341

43

3

87

2

54

1

6

8

4

76

2

5

1

3DC COM

+12VDC

TIP VOLTS

-OUT SENSE

I SENSE

TIP SENSE

CSR

(71)

(77)

(70)

(73)(74)(75)

(72)

8

2

5

3

1

76

4

76

8

54

1

32

P33J33 J39P39

P26

J25

J30

J31

J26 12

12

12

12 2

P25

P30

P31

21

21

21

1

E5

E13

E18

E6E8

E14E16

E15

E7

E4

E23

E20

E30

E10

E27

E32

GATEDRIVE

GATEDRIVE

GATEDRIVE

GATEDRIVE

E12A

E17A

E19A

E21A

E9A

E11A

E9B

E11B

E19B

E21B

E12B

E17B



E52 E47

2

1

2

1

2

1

E5E6

(STANDARD)


(FILTERING)

28VAC B28VAC A

R30

F1T1

K1K1

28VAC A28VAC B

28VAC A

28VAC BGND

TO BIAS SUPPLY

FAN

INRUSH

K1

K2


K4

K5

CONTACTOR ON

K5

SOLENOID ON

K4

PRESS GOOD

8

21

43

ATC RECEIVER

ATC MALECONNECTOR


(33)

SENSECURRENT

MODE SW

RAR OFF(46)

(6/10A 600V)

(0 ohm)

K2

J43

(PILOT PCB)(F9)

(TS1)(TS2)

SOL2BA T6

11 15

6 10

PRI

SEC

WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

FACTORY INSTALLED OPTIONAL TORCH MOUNTED GAS SOLENOID

57

57

ASSY 19X1913 - CM101LOGIC

ASSY 19X1932 - CM81

E1E1

24

12

23

1314

2527

24567

1

28

24

12

23

1314

2527

24567

1

28

E33E33 E3E3

tt

E2E2

Art # A-07153


A

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,42X1136Friday, January 27, 2006

1 1


CM81/101 208/230V SYSTEM11:05:29

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 208/230V SYSTEM11:05:29

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 208/230V SYSTEM11:05:29

THERMAL DYNAMICS

D


THRU SCREW TERMINAL

PILOT


CHASSISGND


D.Lilja

CURRENT

L1

NOMMOC CDNOMMOC CD

OUTPUT INDUCTOR

NOTES: UNLESS OTHERWISE SPECIFIED -


(REL) DLL 05/07/03

SENSE


E50AE48A

E53AE54A

E56AE60A

E39A

E34A

E37 E58

DC COM

ISENSE

+12VDCJ40

5

3

76

4

8

21

CSR

1

5

7

3

P40

2

(18)8

4 (17)

(15)(14)

6

(E58)

J28

2

PILOT BOARD

E62

8

1

E58

ASSY 19X2157

5

E49 E45 E35 E61E32

E64E43E62

E36 E57

E63

E34B

E39B

E56BE60B

E50BE48B

E53BE54B

(E62)

(E35)

WORK

TORCH

(E64)(E64)

L1

W1

F1F2

M1M2

TS1TS2

FUSE, 6/10A 600V KTK

MAIN CONTACTOR

OUTPUT INDUCTOR

TEMP. SENSOR, INDUCTORTEMP. SENSOR, IGBT HEATSINKMAIN TRANSFORMER

FAN, 4.5" 220VAC

FUSE, 0.9A, RESETABLE

SWITCH, ON/OFFGAS SOLENOIDPRESSURE SWITCHFAN, 4.5" 220VAC

SWITCH, RUN/SET/RAR

F4

D7B1C1F4F4

C1

E1D1

JUMPER

5897

OK TO MOVE(+)(-)


(+)(-) TORCH SWITCH

INTERFACE

Vo

54

6

1

7

23

8

1817

1920

13

10

16

14

9

15

1211

P4


J2

J1


45

8

23

1

67


54

3

54

6

1

7

23

8

67

19

13

10

16

14

9

15

1211

1817

1817

1920

13

10

16

14

9

15

1211

8

21

20

J4J3

45

23

8

1

67

45

8

32

7

1

OPTIONAL

6

19X2041


DC COMMON+12VDC

CSRP1

OK TO MOVE

+-

AUTOMATION

+-

TORCH SWITCH

SC-11

P3

DC

GAS

AC

TEMP

(LED PCB 19X1604)

J14 P14

7

1

6

32

8

45

1

5

8

4

67

23 3

21 1

23

+-

DC COMMON

DIVIDED OUTPUT


C&G

CPCHOUSING

4

143

126

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS

CSR Vo

E3 E1

}}}

}

C1

D4T5

PS1SOL1

SW2SW1

F3B2

ECO 101136

RAR OFF

3(46)

(47)(48)(49)

(51)(52)

(TS2)(TS1)

(NEG)

(56)(57)

(58)(59)

(60)(61)

(62)(63)

(64)

12

(52)(51)

J1

HAS 02/11/04ECO 101314ABECO 101429 HAS 06/09/04AC

CONTROL IS USED WITHWHEN REMOTE CURRENT

(REPLACES CONNECTIONSAUTOMATION


FROM J27 TO J14)


05/07/03


(C1)(MODE SW)

(CSR)

(CSR) (NEG)

AA

ECO 101614AD HAS 03/22/05AE ECO B028 RS 01/09/06

AF ECO B016 RWH 01/27/06

Art # A-07153


A

APPENDIX 30: 400 / 415V / 460V SYSTEM SCHEMATIC

For Power Supplies and SL100 Torches (without solenoid on mounting tube)

Art # A-03600

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18V

+18V

415/400

AC

(5)

(3)

2

SE

C

2

GAS

2

DC

ASSY 19X1929 (460V)

GATEDRIVE

2

ON/OFF SW

CHASSIS GND

1


W11

TEMP

W1

1

(1)

1

W1

(4)

PR

I

(2)


IGBTHEATSINKTEMP

INDUCTORTEMP

J29

TS1

J14

P18 J18

FAN1

FAN2

M1

M2

J15P15

1

34

2

P11 J11

BA

INPUT DIODEASSY 19X2073 IGBT BOARD

ASSY 19X1756

MAIN TRANSFORMER

J7B

J3B

J7A

J3A

P3B

P7B

P3A

P7A

E22

TESTCONN

P24

W1

PS1

SOL1 GASSOLENOID

PRESSURESWITCH

MAINCONTACTOR

T5

PR

I

SE

C

P14 J27P27

J33 P33 P39 J39


(STANDARD)

400V3 PHASEINPUT

GATEDRIVE

GATEDRIVE

GATEDRIVE

11

22

11

22

212223




CURRENT SENSE

CURRENT SENSE RTN

TIP VOLTS

+12V

TORCH SW

PRESS GOOD

POT WIPER

RUN/SETTIP SENSE

CSR

2425262728293031

ISENSE3233

CURRENT SENSE RTN

343536

CURRENT SENSE

OVERTEMP

OVTEMP

+12VDC

DC OK

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

POT HIGH

+12VDC

AC OK

DC COM

TORCH SW RTN

4

EXTENDER

5

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

21222324252627282930313233343536

45

3

6

12

9

15

10

14

16

13

1920

1718

11

8

12

45

3

67

12

9

15

10

14

16

D13

13

1920

1718

11

8

12

21222324252627282930313233343536

7

D33

ASSY 19X1913 - CM101

DC COMW1 ON

D25GAS ON

DC COMDC COM

P13 J12 J43P1

INV ON

DRAG ON

SW ON

ASSY 19X1775

LOGIC

ASSY 19X1932 - CM81

8

3

5

2

7

1

4

6

8

67

4

1

5

23

DC COM

TIP VOLTS

+12VDC

I SENSE

-OUT SENSE

CSR

TIP SENSE(71)(70)

(77)

(75)(74)(73)(72)

8

3

5

2

7

1

4

6

8

67

1

45

23

PIP3

5

21

4

6 6

1

45

23

8TORCH SW

TORCH SW RTN

PIPPIP RTN

2

TORCHSW

(78)(79)

(80)(81)

J34 P341

43

J23

321

8

3

5

2

7

1

4

6

J24

8

67

1

45

23

(12)(13)

(11)(10)

(8)(9)

J25

J30

J31

J26 12

12

12

12 2

P25

P30

P31

21

21

21

1

TS2

P32 J321

21

2

P29

NTC

1234

1

4

23

(25)(24)

28VAC B

SET

(21)(22)28VAC A(23)

SW1

SW2

(26) 8

3

5

2

7

1

4

6 28VAC B28VAC A

8

67

1

45

23

230V

(6)(6)

(7)230V (7)

3

5

21

4

6 6

1

45

23

1

34

2400V 'CE' VERSIONINCLUDES IN-LINEEMC FILTER


E12A

E17A

E19A

E21A

E9A

E11A

E12B

E17B

E19B

E21B

E9B

E11B

E52 E47

E3E2E1

E5

E13

E18

E6E8

E14E16

E15

E7

E4

E23

E20

E30

P26

E10

E27

E328

67

4

1

5

23

(36)

(38)(37)

8

65

23

1

4

78

3

5

2

7

1

4

6

(35)

(41)(40)(39)

(42) 8

67

1

45

23

+12VPOT LOW

OVERTEMP

POT WIPERPOT HIGH

DC

GASAC

E5E6

(FILTERING)

R29 (415/460/600V)

R78 (400V)

R30 (208/230V)

F1

T1

K2

K1K1

28VAC A28VAC B

28VAC A

28VAC BGND

SEE TABLE 1 FORF1, R29,R30 & R78


TO BIAS SUPPLY

FAN

INRUSH

K1

K2

CONTACTOR ON

K5

SOLENOID ON

K4

K5

K4F2, 0.9A,(RESETABLE)

PRESS GOOD

8

21

43

ATC RECEIVER

ATC MALECONNECTOR

SENSECURRENT

MODE SW

RAR OFF

RUN

(46)

L1

L2

L3

E33

(PILOT PCB)(F9)

(TS1)

(TS2)

ARC HOLD

E34E36E35

28VAC A28VAC B

ARC HOLD

INPUT

/4603 PHASE

INPUT1 PHASE208/230V

MAIN BOARDASSY 19X1930 (400V)ASSY 19X2228 (415V)

24

12

23

1314

2527

24567

1

28

24

12

23

1314

2527

24567

1

28

tt


AArt # A-03600

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,42X1135Friday, June 10, 2005

1 1


CM81/101 400/415/460V SYSTEM11:05:29

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 400/415/460V SYSTEM11:05:29

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 400/415/460V SYSTEM11:05:29

THERMAL DYNAMICS

D


THRU SCREW TERMINAL

PILOT


(E62)

CHASSIS GND

COMP DESCRIPTION LOCATIONSEE CHART 1

D.Lilja

CURRENT

L1

DC COMMON DC COMMON

OUTPUT INDUCTOR

NOTES: UNLESS OTHERWISE SPECIFIED -1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS


REDRAWN-NO CHGS 05/07/03

SENSE


04/10/0304/04/03DAT

HASECO 100864ECO 100857

ACAB

W1

L1

F1F2

SW1SW2

M1M2PS1SOL1

T5TS1TS2

MAIN CONTACTOR

TEMP. SENSOR, IGBT HEATSINKTEMP. SENSOR, INDUCTOR

OUTPUT INDUCTOR

MAIN TRANSFORMER

FAN, 4.5" 220VAC

PRESSURE SWITCHGAS SOLENOIDSWITCH, ON/OFFSWITCH, RUN/SET/RAR

FAN, 4.5" 220VAC

F4

D7

B2

B1C1F4F4C1C1D4

E1

F3

D1

1

5

J28

7

23

P40

2

(18)

PILOT BOARD

8

4

E62

(17)

8

1

E58

(15)

ASSY 19X2157

(14)

65

DC COM

ISENSE

+12VDCJ40

5

3

76

4

8

21

CSR

(E35)

WORK

TORCH

(E64)(E64)

DLL

E50BE48B

E53BE54B

E34BE39B

E56BE60B

E36 E57

E49 E45E62

E35E43 E64

E32 E61

E58E37

E50AE48A

E53AE54A

E56AE60A

E34AE39A

E63

(E58)JUMPER

5897

OK TO MOVE(+)(-)


(+)(-) TORCH SWITCH

Vo

54

6

1

7

23

8

1817

1920

13

10

16

14

9

15

1211

P4


J1

J2


45

8

23

1

67


54

3

6

54

1

7

23

8

6

19

13

7

10

16

14

9

15

1211

1817

1817

1920

13

10

16

14

9

15

1211

8

21

20

J4J3

45

23

8

1

67

45

8

32

7

1

19X2041

6TORCH SW -TORCH SW +

DC COMMON+12VDC

CSRP1

OK TO MOVE

+-

+-

TORCH SWITCH

SC-11

P3

DC

GAS

AC

TEMP

(LED PCB 19X1604)

J14 P14

7

1

6

32

8

45

1

5

8

4

67

23 3

21 1

23

+-

DC COMMON

DIVIDED OUTPUT


C&G

CPCHOUSING

4

143

126

E3 E1

CSR Vo

}}}

}

19X1930 19X1929400V 460V

ZERO-OHM

ZERO-OHM115X465-2

R78

R29

4/10, 500V21X186

F1 1/4A, 500V21X183

0.9A, (RESETABLE)

115X465-2

X X X X X

X X X X X

TABLE 1

X X X X X X X X X XR30

ECO 101136AD 10/22/03HAS

RAR OFF

3

(47)(48)(49)

(CSR)(51)(52)

(TS2)(TS1)

(NEG)

(56)(57)

(58)(59)

(60)(61)

(62)(63)

(64)

(46)

(51)(52) 1

2J1

ECO 101314AE 02/11/04HAS

WHEN REMOTE CURRENTCONTROL IS USED WITHAUTOMATION(REPLACES CONNECTIONSFROM J27 TO J14)


AF ECO 101429 06/09/04HAS


05/07/03

OPTIONALAUTOMATIONINTERFACE


(MODE SW)(C1)

(CSR) (NEG)

AG ECO 101614 03/22/05HAS

TIP

TIP

99 ARC HOLD25

2221

2423

26

AA

OHMIC SENSE RELAYARC HOLDARC HOLD RETURN

}

(TIP)

AH ECO 101714 HAS 05/23/05AI ECO 101726 HAS 06/10/05

ZERO-OHM115X465-2

X X X X X

X X X X X

4/10, 500V21X186

415V19X2228

E65E65


A

APPENDIX 31: 400 / 415V / 460V SYSTEM SCHEMATIC


1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18V

+18V

415/400V

AC

(5)

(3)

2

SE

C

2

GAS

2

DC

ASSY 19X1929 (460V)

GATEDRIVE

2

ON/OFF SW

CHASSIS GND

1


W11

TEMP

W1

1

(1)

1

W1

(4)

PR

I

(2)


IGBTHEATSINKTEMP

INDUCTORTEMP

J29

TS1

J14

P18 J18

FAN1

FAN2

M1

M2

J15P15

1

34

2

P11 J11

BA

INPUT DIODEASSY 19X2073 IGBT BOARD

ASSY 19X1756

MAIN TRANSFORMER

J7B

J3B

J7A

J3A

P3B

P7B

P3A

P7A

E22

TESTCONN

P24

W1

PS1

SOL1

GASSOLENOID

PRESSURESWITCH

MAINCONTACTOR

T5

PR

I

SE

C

P14 J27P27

J33 P33 P39 J39


(STANDARD)

400V3 PHASEINPUT

GATEDRIVE

GATEDRIVE

GATEDRIVE

11

22

11

22

212223




CURRENT SENSE

CURRENT SENSE RTN

TIP VOLTS

+12V

TORCH SW

PRESS GOOD

POT WIPER

RUN/SETTIP SENSE

CSR

2425262728293031

ISENSE3233

CURRENT SENSE RTN

343536

CURRENT SENSE

OVERTEMP

OVTEMP

+12VDC

DC OK

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

POT HIGH

+12VDC

AC OK

DC COM

TORCH SW RTN

4

EXTENDER

5

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

21222324252627282930313233343536

45

3

6

12

9

15

10

14

16

13

1920

1718

11

8

12

45

3

67

12

9

15

10

14

16

D13

13

1920

1718

11

8

12

21222324252627282930313233343536

7

D33

ASSY 19X1913 - CM101

DC COMW1 ON

D25GAS ON

DC COMDC COM

P13 J12 J43P1

INV ON

DRAG ON

SW ON

ASSY 19X1775

LOGIC

ASSY 19X2284 - CM818

3

5

2

7

1

4

6

8

67

4

1

5

23

DC COM

TIP VOLTS

+12VDC

I SENSE

-OUT SENSE

CSR

TIP SENSE(71)(70)

(77)

(75)(74)(73)(72)

8

3

5

2

7

1

4

6

8

67

1

45

23

PIP3

5

21

4

6 6

1

45

23

8TORCH SW

TORCH SW RTN

PIPPIP RTN

2

TORCHSW

(78)(79)

(80)(81)

J34 P341

43

J23

321

8

3

5

2

7

1

4

6

J24

8

67

1

45

23

(12)(13)

(11)(10)

(8)(9)

J25

J30

J31

J26 12

12

12

12 2

P25

P30

P31

21

21

21

1

TS2

P32 J321

21

2

P29

NTC

1234

1

4

23

(25)(24)

28VAC B

SET

(21)(22)28VAC A(23)

SW1

SW2

(26) 8

3

5

2

7

1

4

6 28VAC B28VAC A

8

67

1

45

23

230V

(6)(6)

(7)230V (7)

3

5

21

4

6 6

1

45

23

1

34

2400V 'CE' VERSIONINCLUDES IN-LINEEMC FILTER


E12A

E17A

E19A

E21A

E9A

E11A

E12B

E17B

E19B

E21B

E9B

E11B

E52 E47

E3E2E1

E5

E13

E18

E6E8

E14E16

E15

E7

E4

E23

E20

E30

P26

E10

E27

E328

67

4

1

5

23

(36)

(38)(37)

8

65

23

1

4

78

3

5

2

7

1

4

6

(35)

(41)(40)(39)

(42) 8

67

1

45

23

+12VPOT LOW

OVERTEMP

POT WIPERPOT HIGH

DC

GASAC

E5E6

(FILTERING)

R29 (415/460/600V)

R78 (400V)

R30 (208/230V)

F1

T1

K2

K1K1

28VAC A28VAC B

28VAC A

28VAC BGND

SEE TABLE 1 FORF1, R29,R30 & R78


TO BIAS SUPPLY

FAN

INRUSH

K1

K2

CONTACTOR ON

K5

SOLENOID ON

K4

K5

K4F2, 0.9A,(RESETABLE)

PRESS GOOD

8

21

43

ATC RECEIVER

ATC MALECONNECTOR

SENSECURRENT

MODE SW

RAR OFF

RUN

(46)

L1

L2

L3

E33

(PILOT PCB)(F9)

(TS1)

(TS2)

ARC HOLD

E34E36E35

28VAC A28VAC B

ARC HOLD

INPUT

/460V3 PHASEINPUT

1 PHASE208/230V

MAIN BOARDASSY 19X1930 (400V)ASSY 19X2228 (415V)

SOL2BA


57

57

PRI

SEC

11 15

6 10

T6


ASSY 19X2285 - CM101ASSY 19X1932 - CM81

24

12

23

1314

2527

24567

1

28

24

12

23

1314

2527

24567

1

28

tt

Art # A-07152


A

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 400/415/460V SYSTEM

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 400/415/460V SYSTEM

THERMAL DYNAMICS

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1


CM81/101 400/415/460V SYSTEM

THERMAL DYNAMICS

D


THRU SCREW TERMINAL

PILOT


(E62)

CHASSIS GND

COMP DESCRIPTION LOCATIONSEE CHART 1

D.Lilja

CURRENT

L1

NOMMOC CDNOMMOC CD

OUTPUT INDUCTOR



SENSE


01/09/06RSECO B028

W1

L1

F1F2

SW1SW2

M1M2PS1SOL1

T5TS1TS2

MAIN CONTACTOR


OUTPUT INDUCTOR

MAIN TRANSFORMER

FAN, 4.5" 220VAC

PRESSURE SWITCHGAS SOLENOIDSWITCH, ON/OFFSWITCH, RUN/SET/RAR

FAN, 4.5" 220VAC

F4

D7

B2

B1C1F4F4C1C1D4

E1

F3

D1

1

5

J28

7

23

P40

2

(18)

PILOT BOARD

8

4

E62

(17)

8

1

E58

(15)

ASSY 19X2157

(14)

65

DC COM

ISENSE

+12VDCJ40

5

3

76

4

8

21

CSR

(E35)

WORK

TORCH

(E64)(E64)

E50BE48B

E53BE54B

E34BE39B

E56BE60B

E36 E57

E49 E45E62

E35E43 E64

E32 E61

E58E37

E50AE48A

E53AE54A

E56AE60A

E34AE39A

E63

(E58)JUMPER

5897

OK TO MOVE(+)(-)


(+)(-) TORCH SWITCH

Vo

54

6

1

7

23

8

1817

1920

13

10

16

14

9

15

1211

P4


J1

J2


45

8

23

1

67


54

3

6

54

1

7

23

8

6

19

13

7

10

16

14

9

15

1211

1817

1817

1920

13

10

16

14

9

15

1211

8

21

20

J4J3

45

23

8

1

67

45

8

32

7

1

19X2041

6TORCH SW -TORCH SW +

DC COMMON+12VDC

CSRP1

OK TO MOVE

+-

+-

TORCH SWITCH

SC-11

P3

DC

GAS

AC

TEMP

(LED PCB 19X1604)

J14 P14

7

1

6

32

8

45

1

5

8

4

67

23 3

21 1

23

+-

DC COMMON

DIVIDED OUTPUT


C&G

CPCHOUSING

4

143

126

E3 E1

CSR Vo

}}}

}

19X1930 19X1929400V 460V

ZERO-OHM

ZERO-OHM115X465-2

R78

R29

4/10, 500V21X186

F1 1/4A, 500V21X183

0.9A, (RESETABLE)

115X465-2

X X X X X

X X X X X

TABLE 1

X X X X XX X X X XR30

RAR OFF

3

(47)(48)(49)

(CSR)(51)(52)

(TS2)(TS1)

(NEG)

(56)(57)

(58)(59)

(60)(61)

(62)(63)

(64)

(46)

(51)(52) 1

2J1




05/07/03



(MODE SW)(C1)

(CSR) (NEG)

TIP

TIP

99 ARC HOLD25

2221

2423

26

AJ

OHMIC SENSE RELAYARC HOLDARC HOLD RETURN

}

(TIP)

ZERO-OHM115X465-2

X X X X X

X X X X X

4/10, 500V21X186

415V19X2228

AK ECO B016 RWH 01/27/06

E65E65

Art # A-07152


A

APPENDIX 32: 600V SYSTEM SCHEMATIC

For Power Supplies and SL100 Torches (without solenoid on mounting tube)1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18V

+18V

(22)

600VAC3 PHASEINPUT

TIP SENSEP1

(77)

AC

(23)

(5)

(75)

(3)

230V

(74)

(26)

SE

C

GAS

(73)

(7)

GATEDRIVE

(72)

DC


GATEDRIVE

ON/OFF SW

CHASSIS GND

(71)

(25)(24)

MODE SW


(70)

W1

3

28VAC B

28VAC B

SET

TIP VOLTS

D13

D33

+12VDC

(6)

TEMP

W1(1)

I SENSE

2

-OUT SENSE

(21)

D25

1

W1

RUN

(4)

PR

I

(2)

CSR

28VAC A


INV ON

DRAG ON

(6)

(7)

EXTENDER

28VAC A

SW1

SW2

IGBTHEATSINKTEMP

TS2

INDUCTORTEMP

NTC

1

43

PIP

DC COM

8

(78)(79)

(80)(81)

ASSY 19X1775

LOGIC

ASSY 19X1932 - CM81

P13 J12 J43

P32

P29 J29

J32TS1

J14

P18 J18

FAN1

FAN2

M1

M2

J15P15

P11 J11

230V

(12)(13)

(11)(10)

(8)BA

(9)


J25 P25

J30 P30

J31 P31

21J26 P261

ASSY 19X1815

MAIN TRANSFORMER

J7B

J3B

J7A

J3A

P3B

P7B

P3A

P7A

E22

J23

TESTCONN

28VAC A

28VAC BGND

J24 P24

W1

PS1

SOL1 GASSOLENOID

PRESSURESWITCH

MAINCONTACTOR

T5

PR

I

SE

C

P14 P27

J34 P34

J33 P33 P39 J39

ASSY 19X1913 - CM101

E3E2E1

E32

E10

E27

E52 E47

E15

E7

E4

E23

E20

E30

IGBT BOARD

E5

E13

E18

E8

E14E16

E6 E12A

E17A

E19A

E21A

E12B

E17B

E19B

E21B

E9A

E11A

E9B

E11B

2

211

2

211

2

112 2

212223




CURRENT SENSE

CURRENT SENSE RTN

TIP VOLTS

+12V

TORCH SW

PRESS GOOD

POT WIPER

RUN/SETTIP SENSE

CSR

2425262728293031

ISENSE3233

CURRENT SENSE RTN

343536

CURRENT SENSE

OVERTEMP

OVTEMP

+12VDC

DC OK

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

POT HIGH

+12VDC

AC OK

DC COM

TORCH SW RTN

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

21222324252627282930313233343536

45

3

6

12

9

15

10

14

16

13

1920

1718

11

8

12

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

7

DC COMW1 ON

GAS ON

DC COMDC COM

SW ON

(36)

(38)(37)

8

65

23

1

4

78

3

5

2

7

1

4

6

(35)

(41)(40)(39)

(42) 8

67

1

45

23

+12VPOT LOW

OVERTEMP

POT WIPERPOT HIGH

DC

GASAC

8

67

1

45

23

J27

1 122

1234

1

4

23

8

3

5

2

7

1

4

6

8

67

1

45

23

3

5

21

4

6 6

45

23

321

4

1

4

23

8

3

5

2

7

1

4

6

8

67

1

45

23

3

5

21

4

6 6

1

45

23

8

3

5

2

7

1

4

6

8

67

1

45

23

2

1 1

2

2

1 1

2

2

1 1

2

2

1 1

2


PIPPIP RTN

2

TORCH SW

8

3

5

2

7

1

4

6

8

67

1

45

23

ASSY 19X1815IGBT BOARD

GATEDRIVE

GATEDRIVE

E5E6


T1

K2

K1K1

28VAC A28VAC B

(FILTERING)

1

(1/4A 600V)

(0 ohm)


(STANDARD)


K1

K2

CONTACTOR ON

K5

SOLENOID ON

K4

FAN

INRUSH

K4

K5

TO BIAS SUPPLY

PRESS GOOD

8

21

43


SENSECURRENT

RAR OFF(46)

L1

L2

L3

E33

R29

F1

(PILOT PCB)(F9)

(TS2)(TS1)

tt

24

12

23

1314

2527

24567

1

28

24

12

23

1314

2527

24567

1

28

A-06752


A

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,Thursday, March 24, 2005

1 1

11:05:29

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1

11:05:29

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1

11:05:29

THRU SCREW TERMINAL

PILOT

(E58)

19X1757

DC COM

(E62)

CHASSIS GND

(E35)

ISENSE

(14)(15)

(17)

(18)

F1


F2

SW1SW2

FUSE, 1/4A 600V FNQFUSE, 0.9A, RESETABLE

M1M2

FAN, 4.5" 220VAC

B2

B1C1

PS1 PRESSURE SWITCHSOL1 GAS SOLENOID

SWITCH, ON/OFFSWITCH, RUN/SET/RAR

F4F4C1C1

T5 D4TS1TS2 E1

D.Lilja

W1 MAIN CONTACTOR F4


CURRENT

L1

L1 OUTPUT INDUCTOR D7

MAIN TRANSFORMER

DC COMMON DC COMMON

+12VDCJ40 P40

WORK

TORCH

OUTPUT INDUCTOR



(REL) DLL

SENSE

Vo


CM81/101 600V 3PH SYSTEM 42X1134D

AATHERMAL DYNAMICSINDUSTRIAL PARK No. 2WEST LEBANON, NH 03784603-298-5711

E49 E45E62

E35E43

E61 E3 E1

E58E37 E36 E57

E63

J28 PILOT BOARD

8

5


45

8

23

1

67

3

54

678

21

5

3

76

4

8

21

CSR

JUMPER

E58 E62

E34AE39A

E50A

E56AE60A

E54AE53A

E48A

E34BE39B

E50B

E48B

E53BE54B

E56BE60B

ASSEMBLYOUTPUT DIODE

19X1757ASSEMBLYOUTPUT DIODE

E64

(E64)(E64)

F3

FAN, 4.5" 220VAC

D1

J2

J1

ALTERNATE 20-PIN HEADER20-POSITION TERMINAL STRIP

54

3

54

6

1

7

23

8

67

19

13

10

16

14

9

15

1211

1817

1817

1920

13

10

16

14

9

15

1211

8

21

20

J4

J3

45

23

8

1

67

45

8

32

7

1


6

19X2041


DC COMMON+12VDC

CSRP1

OK TO MOVE

+-

+-

TORCH SWITCH

P3

321 1

23

Vo

DC

GAS

AC

TEMP

(LED PCB 19X1604)

J14 P14

7

1

6

32

8

45

1

5

8

4

67

23

54

6

1

7

23

8

1817

1920

13

10

16

14

9

15

1211

P4

SC-11

+-

DC COMMON

DIVIDED OUTPUT


C&G

CPCHOUSING

4

143

1265897

OK TO MOVE(+)(-)


(+)(-) TORCH SWITCH

ASSY 19X2157

}}}

}

E32

ECO 101136

CSR

RAR OFF

3(46)

(47)(48)(49)

(CSR)(51)(52)

(TS2)(TS1)(NEG)

(56)(57)

(58)(59)

(60)(61)

(62)(63)

(64)

21

21 J1(52)

(51)

HASECO 101314ABHASECO 101429AC



05/07/03

02/11/0405/07/03

06/09/04



(MODE SW)(C1)

(NEG)(CSR)

ECO 101614 HASAD 03/22/05AE ECO 101664 HAS 03/24/05

A-06752


A

APPENDIX 33: 600V SYSTEM SCHEMATIC


1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18V

+18V

(22)

600VAC3 PHASEINPUT

TIP SENSEP1

(77)

AC

(23)

(5)

(75)

(3)

230V

(74)

(26)

SEC

GAS

(73)

(7)

GATEDRIVE

(72)

DC


GATEDRIVE

ON/OFF SW

CHASSIS GND

(71)

(25)(24)

MODE SW


(70)

W1

3

28VAC B

28VAC B

SET

TIP VOLTS

D13

D33

+12VDC

(6)

TEMP

W1(1)

I SENSE

2

-OUT SENSE

(21)

D25

1

W1

RUN

(4)

PRI

(2)

CSR

28VAC A


INV ON

DRAG ON

(6)

(7)

EXTENDER

28VAC A

SW1

SW2

IGBTHEATSINKTEMP

TS2

INDUCTORTEMP

NTC

1

43

PIP

DC COM

8

(78)(79)

(80)(81)

ASSY 19X1775

P13 J12 J43

P32

P29 J29

J32TS1

J14

P18 J18

FAN1

FAN2

M1

M2

J15P15

P11 J11

230V

(12)(13)

(11)(10)

(8)(9)


J25 P25

J30 P30

J31 P31

21J26 P261

ASSY 19X1815

MAIN TRANSFORMER

J7B

J3B

J7A

J3A

P3B

P7B

P3A

P7A

E22

J23

TESTCONN

28VAC A

28VAC BGND

J24 P24

W1

PS1

GASSOLENOID

PRESSURESWITCH

MAIN CONTACTOR

T5

PRI

SEC

P14 P27

J34 P34

J33 P33 P39 J39

E3E2E1

E32

E10

E27

74E25E

E15

E7

E4

E23

E20

E30

IGBT BOARD

E5

E13

E18

E8

E14E16

E6

E12A

E17A

E19A

E21A

E12B

E17B

E19B

E21B

E9A

E11A

E9B

E11B

2

211

2

211

2

112 2

212223




CURRENT SENSE

CURRENT SENSE RTN

TIP VOLTS

+12V

TORCH SW

PRESS GOOD

POT WIPER

RUN/SETTIP SENSE

CSR

2425262728293031

ISENSE3233

CURRENT SENSE RTN

343536

CURRENT SENSE

OVERTEMP

OVTEMP

+12VDC

DC OK

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

POT HIGH

+12VDC

AC OK

DC COM

TORCH SW RTN

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

21222324252627282930313233343536

45

3

6

12

9

15

10

14

16

13

1920

1718

11

8

12

45

3

67

12

9

15

10

14

16

13

1920

1718

11

8

12

21222324252627282930313233343536

7

DC COMW1 ON

GAS ON

DC COMDC COM

SW ON

(36)

(38)(37)

8

65

23

1

4

78

3

5

2

7

1

4

6

(35)

(41)(40)(39)

(42) 8

67

1

45

23

+12VPOT LOW

OVERTEMP

POT WIPERPOT HIGH

DC

GASAC

8

67

1

45

23

J27

1 122

1234

1

4

23

8

3

5

2

7

1

4

6

8

67

1

45

23

3

5

21

4

6 6

45

23

321

4

1

4

23

8

3

5

2

7

1

4

6

8

67

1

45

23

3

5

21

4

6 6

1

45

23

8

3

5

2

7

1

4

6

8

67

1

45

23

2

1 1

2

2

1 1

2

2

1 1

2

2

1 1

2


PIPPIP RTN

2

TORCH SW

8

3

5

2

7

1

4

6

8

67

1

45

23

ASSY 19X1815IGBT BOARD

GATEDRIVE

GATEDRIVE

E5E6


T1

K2

K1K1

28VAC A28VAC B

(FILTERING)

1

(3/10A 600V)

(0 ohm)


(STANDARD)


K1

K2

CONTACTOR ON

K5

SOLENOID ON

K4

FAN

INRUSH

K4

K5

TO BIAS SUPPLY

PRESS GOOD

8

21

43

ATC RECEIVER

ATC MALECONNECTOR

SENSECURRENT

RAR OFF(46)

L1

L2

L3

E33

R29

F1

(PILOT PCB)(F9)

(TS2)(TS1)

T6

SOL1BA

11 15

6 10

PRI

SEC

SOL2BA

57

57



ASSY 19X1913 - CM101LOGIC

ASSY 19X1932 - CM81ASSY 19X2285 - CM101

ASSY 19X2284 - CM81

tt

24

12

23

1314

2527

24567

1

28

24

12

23

1314

2527

24567

1

28

Art # A-07151


A

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,Friday, January 27, 2006

1 1DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1

THRU SCREW TERMINAL

PILOT

(E58)

19X1757

DC COM

(E62)

CHASSIS GND

(E35)

ISENSE

(14)(15)

(17)

(18)

F1


F2

SW1SW2

FUSE, 3/10A 600V FNQ-RFUSE, 0.9A, RESETABLE

M1M2

FAN, 4.5" 220VAC

B2

B1C1

PS1 PRESSURE SWITCHSOL1 GAS SOLENOID

SWITCH, ON/OFFSWITCH, RUN/SET/RAR

F4F4C1C1

4D5TTS1

1E2ST

D.Lilja

W1 MAIN CONTACTOR F4


CURRENT

L1

L1 OUTPUT INDUCTOR D7

MAIN TRANSFORMER

DC COMMON DC COMMON

+12VDCJ40 P40

WORK

TORCH

OUTPUT INDUCTOR



(REL) DLL

SENSE

Vo


CM81/101 600V 3PH SYSTEM 42X1134D

AA THERMAL DYNAMICSINDUSTRIAL PARK No. 2WEST LEBANON, NH 03784603-298-5711

54E94EE62

E35E43

E61 E3 E1

E58E37 E36 E57

E63

J28 PILOT BOARD

8

5


45

8

23

1

67

3

54

678

21

5

3

76

4

8

21

CSR

JUMPER

E58 E62

E34AE39A

E50A

E56AE60A

E54AE53A

E48A

E34BE39B

E50B

E48B

E53BE54B

E56BE60B

ASSEMBLYOUTPUT DIODE

19X1757ASSEMBLYOUTPUT DIODE

E64

(E64)(E64)

F3

FAN, 4.5" 220VAC

D1

J2

J1

ALTERNATE 20-PIN HEADER20-POSITION TERMINAL STRIP

54

3

54

6

1

7

23

8

67

19

13

10

16

14

9

15

1211

1817

1817

1920

13

10

16

14

9

15

1211

8

21

20

J4

J3

45

23

8

1

67

45

8

32

7

1


6

19X2041


DC COMMON+12VDC

CSRP1

OK TO MOVE

+-

+-

TORCH SWITCH

P3

321 1

23

Vo

DC

GAS

AC

TEMP

(LED PCB 19X1604)

J14 P14

7

1

6

32

8

45

1

5

8

4

67

23

54

6

1

7

23

8

1817

1920

13

10

16

14

9

15

1211

P4

SC-11

+-

DC COMMON

DIVIDED OUTPUT


C&G

CPCHOUSING

4

143

1265897

OK TO MOVE(+)(-)


(+)(-) TORCH SWITCH

ASSY 19X2157

}}}

}

E32

ECO 101136

CSR

RAR OFF

3(46)

(47)(48)(49)

(CSR)(51)(52)

(TS2)(TS1)(NEG)

(56)(57)

(58)(59)

(60)(61)

(62)(63)

(64)

21

21 J1(52)

(51)

HASECO 101314ABHASECO 101429AC



05/07/03

02/11/0405/07/03

06/09/04



(MODE SW)(C1)

(NEG)(CSR)

ECO 101614 HASAD 03/22/05AE ECO 101664 HAS 03/24/05AF RSECO B028 01/09/06AG ECO B016 RWH 01/27/06

Art # A-07151

AH ECO B077 RWH 07/31/06

APPENDIX 34: Publication History

Release Rev. Changes

1/3/05 - Released to production.

2/14/05 - Updated per ECO 101610, adding parts to Spare parts kits.

6/17/05 - Added 415V CE units, ECO 101726.

9/15/05 - Updated 208/230V and 600V schematics, updated work cable clamp.

Feb. 1, 2006 - Added system schematics for system w/ SL100SV Torches (w/ solenoid onmounting tube). Added torch connection diagram and torch pinout diagramsfor torch w/ solenoid. Added transformer for power supplies supporting torchw/ solenoid. Added catalog numbers for torches & leads w/ solenoid & forreplacement leads for torches w/ solenoid. Added publication history to manual.

Mar. 29, 2006 AA Dropped references to leads extensions. Started using new cover style.

April 17, 2006 AB Updated torque spec for input diode to 35 in-lb / 3.95 Nm.

Oct. 5, 2006 AB.01 Added patent information and newer revision control to include two numbers.

Mar. 14, 2007 AC.01 Updated 600 volt schematic to show new fuse.

April 2, 2007 AD.01 Revised Art - Appendix 4, Torch Pin - Out Diagrams:A. Power Supply and SL100SV (without Solenoid) Art A-03900B. Power Supply and SL100SV Torch (with Solenoid) Art A-07114added text to Callout #'s: 3 & 4: Not Used, updated inside & rear cover.

Thermadyne USA2800 Airport RoadDenton, Tx 76207 USATelephone: (940) 566-2000800-426-1888Fax: 800-535-0557Email: [email protected]

Thermadyne Canada2070 Wyecroft RoadOakville, OntarioCanada, L6L5V6Telephone: (905)-827-1111Fax: 905-827-3648

Thermadyne EuropeEurope BuildingChorley North Industrial ParkChorley, LancashireEngland, PR6 7BxTelephone: 44-1257-261755Fax: 44-1257-224800

Thermadyne, ChinaRM 102A685 Ding Xi RdChang Ning DistrictShanghai, PR, 200052Telephone: 86-21-69171135Fax: 86-21-69171139

Thermadyne Asia Sdn BhdLot 151, Jalan Industri 3/5ARawang Integrated Industrial Park - Jln Batu Arang48000 Rawang Selangor Darul EhsanWest MalaysiaTelephone: 603+ 6092 2988Fax : 603+ 6092 1085

Cigweld, Australia71 Gower StreetPreston, VictoriaAustralia, 3072Telephone: 61-3-9474-7400Fax: 61-3-9474-7510

Thermadyne ItalyOCIM, S.r.L.Via Benaco, 320098 S. GiulianoMilan, ItalyTel: (39) 02-98 80320Fax: (39) 02-98 281773

Thermadyne International2070 Wyecroft RoadOakville, OntarioCanada, L6L5V6Telephone: (905)-827-9777Fax: 905-827-9797

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Corporate Headquarters16052 Swingley Ridge RoadSuite 300St. Louis, MO 63017Telephone: 636-728-3000Email: [email protected]

PLASMA CUTTING MACHINE TORCH - Welding … equipment/automated systems … · PLASMA CUTTING...

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